How 3D Digital Twin is Set to Transform Industries in 2025?

Introduction

Imagine having a virtual replica of your factory, construction site, or even an entire facility, enabling you to monitor, simulate, and optimize operations in real time. This is no longer science fiction—it’s the power of 3D digital twins.

As 75% of enterprises have already adopted digital twin technologies (McKinsey), 3D digital twins are emerging as the next step. These models combine AI, IoT, and AR/VR to offer richer visualization, better simulations, and real-time insights, enabling enterprises to replicate and analyze their physical environments more effectively.

3D digital twins are different than the 2D ones. They provide:

• Enhanced visualization: Since 3D models look richer than 2D ones, the user can understand complex data and relations and make informed decisions.
• Improved simulation: 3D digital twins better simulate real-world scenarios than 2D. Thus, users can test various scenarios and improve their preparedness by planning their responses.
• Real-time data access: 3D digital twins connect with different sensors and provide real-time data that improves decision-making.

Read this blog to learn more about 3D Digital Twins.

3D digital twin technology has transformed industries like manufacturing and utilities, making operations more sustainable and efficient.

Let’s learn about its transformative capabilities.

How Does a 3D Digital Twin Work?

Before delving into the challenges that 3D digital twins can solve and their improvements, let’s understand how they work.

• Phase 1—Data Capture: In this phase, we collect high-quality images and sensor data from various equipment using a 3D digital twin platform like Framence. We then use this data to build a virtual layout of the physical object in a 3D model.
• Phase 2 – Create the 3D Digital Twin: We ensure the 3D model covers all the finer nuances of the physical world, such as production, operations, and maintenance. Framence, for instance, helps us define the precise measurements of the objects. This enables the model to represent machines, production lines, and plant layouts accurately.
• Phase 3 – Augment information: To enhance the capabilities of the 3D model, we augment it with documentation, videos, and other informative material. We also provide advanced search functionality to enable users to search for information quickly.
• Phase 4 – Data integration: We integrate the 3D model with third-party systems and applications to collect real-time operational data and improve production, operations, and maintenance.

What Challenges Can 3D Digital Twin Solve?

Since a 3D digital twin captures and processes real-time data better than a 2D one and can build interactive models, there are some challenges that it can solve easily:

• Predict issues and reduce downtime

Enterprises lose revenue due to unexpected downtime and equipment breakdowns. Thus, predictive maintenance is imperative for uninterrupted operations. 3D digital twins provide the maintenance team with a virtual view of the precise location and view of the equipment. This allows them to conduct virtual inspections and identify and solve issues remotely. Additionally, the integrated sensors provide the team with historical and real-time data on the equipment’s health, which helps them analyze potential problems and take pre-emptive measures to solve them.

• Improve safety and operations with immersive training

Training new employees is crucial for a plant or machinery’s smooth operations and safety. Since 3D digital twins leverage technologies like AR/VR, enterprises can create immersive training materials to operate plants or machinery and maintain safety. Unlike conventional training materials, these methods are more interactive, practical, and memorable. Employees can easily retain knowledge and apply them quickly in a physical setup.

The immersive 3D virtual replicas offer a high-resolution view of the plant and machinery, making it easy for employees to gain hands-on experience without interrupting real-world operations. They are presented with realistic scenarios that expose them to various hazards and risks and prepare them for different real-world situations.

• Eliminate silos between teams

Sometimes collaboration can become tedious when different teams work in silos. It can result in communication gaps, misunderstandings, and a longer product development cycle.

3D digital twins provide a unified and collaborative platform that allows teams to share data, collaborate, review the simulated designs and prototypes, iterate fast, and build better products within a short duration. By enhancing cross-collaboration and eliminating silos, enterprises can improve decision-making, reduce the validation cycle, and accelerate the go-to-market speed.

• Optimize operations and maintenance to make them sustainable

Traditional 2D digital twin models do not offer a comprehensive view of the physical objects, making it difficult for enterprises to optimize production and maintenance at an early phase.

Enterprises can optimize operations with 3D digital twins.

A 3D digital twin can:

• Forecast potential failure and improve maintenance
• Simulate visual inspections and ensure timely repair or replacements to avoid unplanned downtime
• Monitor energy consumption and design products that align with the enterprise’s sustainability goals
• Enhance decision-making and drive operational excellence
• Improve planning at the plant

To ensure smooth operations, enterprises must plan and prepare for all situations. 2D digital twins provide limited visibility and scope to analyze various scenarios. 3D digital twins can access real-time data and offer a more comprehensive view of the manufacturing plant. This allows users to test multiple ‘what-if’ scenarios through simulation, analyze the outcomes, and optimize processes. The automotive industry, for instance, can use 3D digital twins to simulate assembly lines, assess production, and find solutions to minimize cycle time and errors. 3D digital twins are also helpful in planning emergencies like evacuating during a fire outbreak and managing risks.

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