Step Into the Future with a Digital Twin

Step Into the Future with a Digital Twin

The European Commission has set out to build a digital twin of our entire planet. Using massive sets of real-world data, the Commission will create a digital replica of Earth that is capable of simulating its environment. Ultimately, it aims to predict environmental disasters before they strike. With this kind of insight, we can react to issues before they are too late.  

Prediction is among the most powerful advantages of digital twins. It’s like having the power to peer into the future. Whether it be saving our planet from crippling events, or simply predicting disastrous manufacturing disruptions, digital twins are a necessary digital transformation technology. . 

As more and more manufacturers undergo digital transformation, they are beginning to adopt digital twin technologies. From space travel to oil refineries, digital twins can benefit any manufacturing operation. 


NASA was the first to develop and use a digital twin when it ran into issues on the Apollo 13 mission. Decades later, NASA has broadened its digital twin usage into building and testing equipment. The company starts with a digital model of new equipment based on real-world parameters, then simulates it in a number of scenarios to predict how it will work once manufactured. Only when tests are successful does NASA produce a physical model. The physical model is then tied back to that digital twin, via sensors, so more simulations can be run based on the equipment’s actual performance. That data is then used to predict maintenance and performance. 


Boeing uses digital twin technology to predict performance of its airline components. The company creates a digital twin of each new plane and feeds it real-world data from every component on the plane. As an aerospace company, maintenance is an incredibly important aspect of the business. If a part fails, the results can be disastrous. Running simulations from the aircraft’s digital twin shows Boeing when a component is at risk of failure. Boeing can then anticipate ahead of time when this will happen and take the necessary steps to fix the problem. 


Chevron is deploying thousands of sensors on its oil field equipment to build a digital twin. The sensors feed data into the digital twin where it then simulates the real-world activity in a digital environment. Equipment breakdowns in the oil fields can lose the company millions of dollars. With the digital twin, workers receive predictions on when the equipment will fail ahead of time. This kind of knowledge prevents unexpected disruptions and keeps operations running smoothly and profitable. 


A4 Systems are experts in developing cyber physical systems. We connect physical assets and processes to the digital world. Using sensors and other methods of data collection, we can create digital twins to predict outcomes for any manufacturer. Digital twins are the future of modern manufacturing.