Imagine if you could peer into the future of a machine—track its wear and tear, predict when it might fail, and fine-tune its performance—all without touching it.
That’s the promise of digital twin modeling: a virtual model that evolves and adapts with its real-world doppelganger.
Unlike static simulations or 3D models, digital twins—developed using expert knowledge—are constantly updated by live data collected from the physical asset they represent, whether that’s a wind turbine, a car, or even a human heart.
This real-time feedback allows engineers to track performance, predict faults before they occur, and plan for short and long-term maintenance with better accuracy.
It’s reported that 29% of global manufacturing companies have either fully or partially implemented a digital twin strategy.
Associate Professor Pietro Borghesani, from UNSW’s School of Mechanical and Manufacturing, says in industries where safety, reliability and cost-efficiency are vital, digital twin modeling is extremely valuable in asset management.
“A digital twin doesn’t just simulate, it lives with the machine,” he says. “You can use the digital history of your machine to control how the asset degradation is evolving and then use that knowledge to streamline your operations.
“Instead of being reactive to what happens to the asset, it allows us to plan—but with better accuracy.”
From wind turbine blades to heartbeats
Digital twins are already being used to monitor complex systems in the manufacturing and energy sectors. However, the technology isn’t confined to large, physical machines.
It’s widely used by construction companies to design and build phases of a structure to uncover issues before they develop and become costly.
In the medical industry, biomedical researchers are also experimenting with digital twins of human organs, such as the heart, to better understand disease progression and to personalize treatments.
“The same principles apply: feed in patient-specific data, update the model continuously, and simulate future outcomes,” says A/Prof. Borghesani
“The only thing that changes is the physics. For a machine, we use dynamics and vibration analysis. For a human heart, it’s…
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