What Is Industry 4.0?
Industry 4.0 is the Fourth Industrial Revolution. It combines AI, IoT, robotics, and automation to connect digital and physical systems. Dassault Systèmes, a leader in digital engineering, explains the Virtual Twin as a living model that links real-world data with simulation, helping businesses predict and optimize outcomes.
We’re living through the Fourth Industrial Revolution (Industry 4.0), where digital, physical, and biological technologies are merging to reshape industries. Innovations like artificial intelligence (AI), the Internet of Things (IoT), and robotics are driving new levels of automation and efficiency across the global economy.
Why Are Digital and Virtual Twins Important?
Manufacturers, in particular, are seizing these opportunities, with two terms becoming central to the conversation: digital twins and virtual twins. While they sound similar, they are different concepts. Understanding the difference matters for manufacturers and engineers.
What Is a Digital Twin?
A digital twin is a virtual model of a physical object or system, used to monitor and improve performance.A digital twin is a real-time digital replica of a physical object, process, or system. It connects through IoT sensors and data streams to mirror real-world behavior. Engineers use it to monitor, predict, and optimize performance. CADimensions helps manufacturers deploy digital and virtual twin solutions, including predictive maintenance and lifecycle management:
- Detect potential failures early
- Optimize performance in real time
- Manage an asset’s lifecycle more effectively
Example of a Digital Twin
For example, a wind turbine can send real-time data on vibrations, weather conditions, and blade wear to its digital twin. Engineers can then use this insight to predict issues before they lead to costly downtime.
What Is a Virtual Twin?
| Aspect | Digital Twin | Virtual Twin |
|---|---|---|
| Scope | Single asset or process | Entire system and interactions |
| Data Source | Real-time IoT sensors | Simulation plus real-time data |
| Use Case | Predict maintenance | Optimize design, operations, and sustainability |
A virtual twin takes the concept further. A virtual twin is a dynamic, multi-scale simulation that connects digital models with real-world data to predict and optimize outcomes. Instead of only mirroring a physical object, it builds a comprehensive virtual environment that includes:
- The physical product itself
- Its surrounding environment
- Behavior and interactions within the system
Example of a Virtual Twin
Imagine an aircraft analysis: engineers could combine the digital twin of its engines with aerodynamic simulations, manufacturing constraints, maintenance schedules, and even pilot training scenarios. The result is a complete, real-time simulation that enables better decision-making and scenario planning.
Who Provides Virtual Twin Platforms?
One of the leaders in this space is Dassault Systèmes, which offers Virtual Twin Experiences through its 3DEXPERIENCE platform and DELMIAWorks. CADimensions works with manufacturers to plan, adopt, and scale these platforms. But what does this mean in practice for manufacturers?
How Do Virtual Twins Add Value in Manufacturing?
In manufacturing, virtual twins deliver value at every stage of the lifecycle — from product design to sustainability:
- Product Design: Simulate and validate designs early to cut down on prototypes and accelerate R&D.
- Production Operations: Optimize factory layouts, reduce bottlenecks, and minimize downtime.
- Supply Chain: Gain end-to-end visibility, test scenarios, and improve forecasting.
- Maintenance: Use predictive insights to extend equipment life and avoid unplanned shutdowns.
- Workforce Training: Create immersive, risk-free environments for onboarding and skills development.
- Sustainability: Model energy use, waste, and emissions to meet compliance and environmental goals.
Closing Thought
Digital twins help manufacturers monitor and predict, but virtual twins empower them to reimagine and transform. As of 2025, manufacturers are rapidly adopting virtual twins to support sustainability and system-level decision-making. The virtual twin is quickly becoming a cornerstone of smart, sustainable manufacturing.
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You Ask, We Answer: Solutions to Common Digital and Virtual Twin Questions
What is the difference between a digital twin and a virtual twin?
A digital twin mirrors a single physical object or process in real time. A virtual twin includes the product, its environment, and interactions, allowing full simulation.
Which industries use virtual twins?
Manufacturing, aerospace, energy, and healthcare are leading adopters, using them for design, operations, and sustainability.
Are digital twins part of Industry 4.0?
Yes. Digital twins are a core Industry 4.0 technology, enabling real-time monitoring and predictive insights for smarter factories.
