50+ Use Cases of Digital Twins Across Industries

October 5, 2023
50+ Use Cases of Digital Twins Across Industries

So, you know how in video games, players often have a "practice mode" where they can try out their strategies before they jump into a real game? Well, a digital twin is like that, but for the manufacturing world.

A digital twin is a virtual copy of a product, process, or system. This twin can mirror the real thing in a digital world. So, if a company is making, let's say, a new smartphone model, they can create a digital twin of that smartphone and its production process first. Cool, huh?

Now, using this digital twin, they can run all sorts of tests and simulations. This could be anything from "What happens if we use this different type of battery?" to "What if we change the order of the assembly line?" It's all done virtually, meaning they don't have to spend money or materials to physically produce these different scenarios.

And it's this specialty of Digital Twin that is attracting companies to them. Businesses across industries have started studying its benefits and implementing them. In fact, the digital twin market size is forecasted to reach $193.7 million by 2030.

Now, keep this in mind as we move forward and discuss the use cases of Digital Twins. 

Common Use Cases of Digital Twin Across Industries

1. Predictive Maintenance & Advanced Diagnostics

Digital twins can predict equipment maintenance needs, showcasing one of the pivotal digital twin use cases in modern industries. By continuously collecting data from the physical asset and applying predictive analytics and machine learning, potential failures or breakdowns can be anticipated, ensuring timely interventions.

Instead of reacting to equipment failures, digital twins allow manufacturers to predict them. By continuously monitoring equipment conditions through sensors, potential issues can be identified and addressed before they escalate, minimizing downtime.

Learn more about predictive maintenance.

2. Decrease Time to Market

By simulating product quality and performance in a virtual environment, manufacturers can identify and rectify issues before moving to production. This not only ensures a higher quality product but also reduces the time it takes to bring it to market.

3. Streamlining Product Development

For industries like manufacturing, digital twins eliminate the need for physical prototyping. This not only reduces development costs but also minimizes the environmental impact associated with prototype waste. 

Efficiency in the production line is crucial for any industry. Digital twins offer a dynamic view of the assembly line, highlighting each step in real time. This virtual representation allows manufacturers to identify potential inefficiencies, test solutions, and optimize the entire production process, ensuring a smoother and more cost-effective outcome.

4. Revolutionising Design & Prototyping

Digital twins are revolutionizing the design process. Engineers can now create virtual models, allowing them to test and validate designs even before the prototyping phase. This virtual environment offers a risk-free space to experiment with different designs, materials, and systems, ensuring optimal performance and aesthetics.

Before diving into the manufacturing phase, digital twins of apparatuses offer a sandbox for developers to experiment with device functionalities. This virtual testing not only minimizes the financial implications of design failures but also ensures the end product's safety and optimal performance.

5. Streamlining Production & Assembly

The assembly of complex components requires precision, making digital twins invaluable in various industries. Digital twins provide a real-time visual representation of the assembly process, allowing manufacturers to identify inefficiencies and streamline workflows. This optimization leads to faster production, fewer errors, and substantial cost savings, demonstrating the versatile applications of digital twins across industries.

6. Updates Product in the Field 

Before deploying an update to the real-world product, you can first try it out on your digital twin. You can see how the update behaves in different scenarios, iron out any kinks, and ensure it delivers the intended benefits. It's like a dress rehearsal for your update. 

This testing process in a digital environment also helps you anticipate how the update will interact with various aspects of the product and the environment in which it's used. Maybe there's a particular setting or condition where the update doesn't work as well as expected.

You can test different versions of an update and see how small changes might improve performance. Furthermore, you can fine-tune the update until it's just right.

7. Streamlined Operations

Streamlining operations is another use case of digital twins you should be aware of. It helps you simulate various operational scenarios, allowing you to understand the effects of different operating parameters. This knowledge can be used to enhance operations, boost efficiency, and increase productivity. 

For instance, simulating an oil extraction process with a digital twin can help pinpoint bottlenecks and fine-tune extraction rates, demonstrating the versatility and practicality of digital twins in optimizing industrial processes.

Manufacturing Industry

Use cases of digital twins in manufacturing

In manufacturing and production, the use cases for digital twins are extensive and transformative. They streamline processes, enhance product quality, and optimize resource allocation. By creating virtual replicas of machinery and production lines, businesses can anticipate issues, reduce costs, and drive innovation.

The widespread adoption of digital twins in manufacturing not only showcases their effectiveness but also underscores their central role in shaping the future of this industry.

Interestingly, the lion's share of the global digital twin market is manufacturing. 

Global digital twin market share

8. Improve Product Quality 

When we consider the automobile industry, designing a new model is challenging. It's like a complex puzzle where every part should fit perfectly. 

Now, a digital twin acts as a virtual sandbox where manufacturers can assemble this puzzle and see how the pieces fit. Manufacturers can make changes quickly if something doesn't align or function properly. 

Also, it's far easier and cheaper to fix it in this digital realm than in the physical world. So, the twin helps enhance product quality by spotting potential snags before they cause real trouble. 

Learn more about the role of digital twins in the automotive industry

9. Reduce Manufacturing Costs 

Imagine being able to play out the whole manufacturing process on a computer before spending a dime on real-world production. This is one of the innovative digital twin use cases that can bring significant value to manufacturers. 

With a digital twin in the manufacturing process, you could see where you might waste resources, where bottlenecks might occur, or even the unnecessary steps in the process. By identifying these, you can adjust your process to avoid potential issues. Thus digital twins provide a cost-effective trial run for your production line. 

10. Reduce Unplanned Downtime 

Every minute a factory is not operational, money is lost, not to mention the delay in delivery to customers. Furthermore, the equipment doesn't give a heads-up before they break down. 

Digital twins can help predict such issues before they happen. They're like a crystal ball that can foresee when a machine might break down, allowing you to fix potential problems before they lead to costly downtime. 

Read more about predictive maintenance to get a better understanding of the matter. 

11. Increase Throughput 

Consider an automobile manufacturer. In a set period, they produce a specific amount of vehicles. But with the increasing demand for their product, they decided to increase production. But their current production rate is not quite up to mark. 

This scenario exemplifies digital twin use cases in the manufacturing sector. Through digital twins, manufacturers can create detailed models of their complex processes. By analyzing these models, they can pinpoint inefficiencies, bottlenecks, and areas of waste, leading to more streamlined and efficient operations.

12. Encourage Innovation

Digital Twins offers a virtual platform where manufacturers can prototype and experiment with new products, eliminating the expenses tied to physical prototyping. This not only conserves resources but also cultivates a culture of innovation through swift experimentation.

13. Optimize Product Performance

Digital twins' use cases are beyond the manufacturing stage, offering continuous monitoring of products even after they have been produced. This ongoing oversight yields valuable insights into how products perform, allowing manufacturers to make necessary adjustments and enhancements for better results.

In the manufacturing sector, digital twin use cases also include optimizing machinery use by collecting data on various aspects. This data-driven approach ensures that machinery is used under optimal conditions, maximizing efficiency and output.

14. Speed New Product Information 

A digital twin lets manufacturers quickly share detailed information about new products. This includes how they are made, the materials to use, and how they will function. It's like having a digital handbook that can drastically reduce the time it takes to get a product from concept to customer. 

15. Ensure Safe Manufacturing

Safety first, right? It is not just because of the legal and financial implications of accidents but also the welfare of the employees. But foreseeing potential hazards isn't always easy. 

Digital twins can help here. 

You can simulate different scenarios to analyze and address potential safety issues ahead of time. For example, if you are introducing a new machine, you can simulate the digital twin of the new machine alongside others. 

You can observe how it interacts and identify any possible safety issues, even before unboxing the real machine. Therefore, through these digital twin use cases you can ensure the overall health and well-being of your workforce.

16. Develop Product Enhancements 

Let's say you have a product out there. It's performing well and loved by the customers. But you saw customer feedback pointing out a missing feature in your product, which your competitor offers. 

What's the best way to test whether the feature fits well with your existing product or not? 

Answer - Digital Twins. 

This scenario highlights one of the practical digital twin use cases where you can try out these enhancements in a digital space. You can monitor how it fits within your product and how well it performs. But most importantly, you can understand whether the addition ruptures the performance of your current product. 

You can make necessary tweaks and tests until you're ready to release an improved version that you're confident customers will love. 

Looking for ways to implement digital twins? Here is a complete guide to help you with it - Digital Twin Implementation

17. Digital Transformation of Enterprises 

Digital twin for better decision-making

When we talk about digital transformation here, we are not essentially talking about enterprises having a website or mobile app. Instead, it's about enhancing the ways the enterprise used to work with a new one. A better one! 

It's like replacing an old rusty bicycle with a sleek new electric one. 

Digital twins blend the physical and digital worlds, optimizing operations and giving powerful insights into business processes. This includes but is not limited to identifying potential bottlenecks, inefficiencies, and areas that need improvement. 

18. Training for New Manufacturing Process

Digital twin in Training for New Manufacturing Process

Training can be costly and risky. Learning new things means there will be mistakes. And mistakes in the real world can be expensive as well as dangerous. 

But with a digital twin, employees can learn new processes in a virtual environment before they're used in the real world, making for a smoother, safer learning curve. This is one of the essential digital twin use cases where manufacturers can enhance worker training, empowering them with the necessary skills and knowledge and mitigating risks associated with on-the-job learning.

Healthcare Industry

Digital twin uses in Healthcare Industry

The integration of digital twins in the healthcare sector promises a paradigm shift, offering a fusion of real-world and virtual data. This convergence facilitates predictive analytics, personalized patient care, and optimized hospital operations, setting the stage for a more efficient and patient-centric healthcare ecosystem.

19. Advancements in Medication

Digital twins of pharmaceutical compounds provide a platform for scientists to tweak or re-engineer drugs, focusing on attributes like particle dimensions and chemical makeup, thereby enhancing their efficacy.

20. Virtual Replication of Medical Facilities

By utilizing past and real-time data, including patient admissions and disease outbreaks, digital twins can predict resource shortages, optimize staff schedules, and manage surgical suites in healthcare. 

This approach not only boosts operational efficiency but also curtails expenses. For instance, stroke patient treatment durations have been reduced by leveraging digital twins for better coordination and resource management.

21. Meet New Regulatory Challenges 

Imagine you're operating a pharmaceutical company. You've got a best-selling medication that has been proven effective and safe. Suddenly, a new regulation rolls out that mandates additional testing or changes in the manufacturing process to ensure the medication's purity. 

It's a significant change, and you have no idea how it might affect your production process. But with a digital twin of your production process, it's not the same. 

This scenario exemplifies how digital twin use cases can be a game-changer in the pharmaceutical industry. With your digital twin, you can simulate the effect of these new regulations on your production line. How will additional testing fit into the process? What changes will need to be made to ensure purity? 

You can experiment with different scenarios and find the most efficient, compliant solution without disrupting your real-world operations. Thus it will help you adapt swiftly to changes and stay compliant. 

Learn more about the role of digital twins in healthcare

22. Virtual Modeling of Human Physiology

By capturing individual-specific data, such as vital signs, digital twins enable a more personalized health monitoring system. This not only empowers patients to keep track of chronic conditions but also enriches doctor-patient interactions with foundational health data. Such granular data also becomes a cornerstone for clinical research and trials.

Digital twins, with their intricate modeling of the human anatomy, allow medical professionals to identify potential health issues even before they manifest. This foresight aids in devising treatment strategies and refining surgical preparations. For example, a unique approach at Linköping University involved creating a digital twin using mice RNA to anticipate medication outcomes.

Automotive Industry

Digital twin use cases in Automotive industry

The automotive industry is undergoing rapid transformation, with advancements in technology reshaping how vehicles are designed, produced, and maintained. Digital twins, serving as virtual replicas of vehicles and their components, are at the forefront of this revolution. They offer the industry a powerful tool to simulate, test, and optimize various processes, ensuring safer, more efficient, and innovative automotive solutions.

23. Testing & Validating Autonomous Vehicles

The rise of autonomous vehicles brings new challenges in ensuring their safety and reliability. Here, digital twins provide a safe virtual environment for testing these vehicles across various scenarios, from busy city streets to challenging weather conditions. This comprehensive testing ensures that autonomous vehicles are road-ready and safe for users.

24. Enhancing Customer Experience

Personalization is key in today's consumer-driven world. Digital twins enable automotive companies to offer tailored vehicle suggestions based on a customer's preferences and driving history. Post-purchase, these virtual replicas can guide owners through troubleshooting steps or even schedule maintenance, ensuring a seamless ownership experience.

Digital twin for customer experience

Suppose you're a customer service representative, and you get a call from a customer who's having trouble with your product. It might be a complex machinery part, a smart home device, or even a car. 

Trying to troubleshoot over the phone, based on verbal descriptions, can be quite challenging, right? Now if you have a virtual replica of the product the customer owns, then it will be a different scenario. 

This virtual model lets you recreate the customer's problem in real time. It's like having the product right there with you, even though it's miles away. 

For example, if a customer says their car’s AC is not cooling properly, you can use the digital twin to mimic the AC's behavior. This lets you identify the problem more accurately than you ever could based on a verbal description alone. 

You can simulate a customer's problem and work out the solution. Or you can offer personalized recommendations based on how they use the product. 

Learn more about how digital twins can help in enhancing CX from our experts. 

25. Optimising Supply Chain Management

Managing the intricate networks of suppliers, manufacturers, and distributors in the automotive industry is a complex task. The ability to replicate the entire supply chain is a pivotal digital twin use case. For example, consider a car manufacturer implementing digital twins to simulate their supply chain. This virtual replication offers insights into material flow, production timelines, and potential bottlenecks. The result is a supply chain that guarantees on-time deliveries, maintains optimal inventory levels and operates with greater efficiency.

Learn more about digital twins revolutionizing supply chain management here.

26. Design Changes to the Production Line 

There are several reasons for the production rate to be low, and one reason is inefficiencies in the workflow. Now, manually it is a gargantuan task to monitor and spot where the issues are. But with a Digital twin of a production process, it is as easy as counting to five. 

A digital twin allows you to play around with your production line design. You can see where the problems are and make the necessary tweaks until you find the most efficient setup. In addition, you can understand the impact of the change you make. 

The result will be a smoother, more efficient production process that saves you time and money. 

Aerospace & Defense

Digital twin use case in Aerospace & Defense

In the defense sector, strategy and preparedness are crucial. Utilizing digital twins allows defense agencies to simulate various scenarios, from potential threats to equipment performance, representing a critical digital twin use case. 

These simulations provide valuable insights, enabling agencies to refine strategies, optimize equipment deployment, and ensure robust defense mechanisms, demonstrating the invaluable role of digital twins in enhancing national security and preparedness.

27. Enhancing Maintenance & Repair Operations (MRO)

Aircraft maintenance is a complex and critical task. Digital twins provide real-time insights into aircraft health, predicting potential issues and optimizing maintenance schedules. This proactive approach reduces unplanned downtimes, extends aircraft lifespan, and ensures optimal flight safety.

28. Enhancing Defense System Simulations

In the defense sector, where strategy and preparedness are of utmost importance, the use of digital twins to simulate various scenarios stands out as a critical application. These simulations provide critical insights, allowing agencies to enhance their strategies, optimize equipment deployment, and strengthen defense mechanisms. This underscores the strategic significance of digital twins in bolstering defense capabilities and readiness.

Oil & Gas

Digital twin use cases in Oil & Gas

The oil and gas sector, a cornerstone of the global economy, faces challenges ranging from market fluctuations to environmental concerns. Here, the digital twin use case, rooted in the Industrial Internet of Things (IIoT), offers transformative solutions. 

By bridging the physical and digital realms, digital twins enable the industry to enhance asset management, boost performance, and minimize costs and unexpected downtimes, showcasing the profound impact of digital twin technology in addressing sector-specific challenges and optimizing operations.

Learn more about the digital twin use cases in the oil and gas industry.

29. Asset Maximization

Digital twins empower operators to make the most of critical assets. For example, a digital twin of an oil reservoir can provide insights into reservoir behavior, enabling better extraction planning and strategies, and leading to improved extraction rates and profitability.

30. Safety Protocols and Emergency Preparedness

The oil and gas industry prioritizes safety. Digital twins can simulate various scenarios to help operators optimize procedures and address potential hazards. For instance, simulating an oil pipeline system can help predict potential leaks, allowing for proactive repairs.

31. Sustainable Operations

With increasing emphasis on environmental responsibility, digital twins assist companies in devising strategies to minimize emissions, manage waste, and adhere to environmental regulations. They can also simulate the effects of new regulations or technologies, aiding the industry's adaptation to evolving standards.

32. Drilling Efficiency

Drilling operations are intricate and expensive. Digital twins can simulate various drilling scenarios, offering insights into optimal strategies. For example, a digital twin can suggest the best drilling speed and direction, enhancing overall accuracy.

33. Reservoir Management

A digital twin of an oil reservoir allows operators to visualize reservoir behavior, refine drilling strategies, and maximize extraction, prolonging the reservoir's lifespan.

34. Supply Chain Streamlining

The oil and gas supply chains are intricate. Digital twins can simulate the entire supply chain, offering a comprehensive view of operations, logistics, and potential bottlenecks.

Energy Sector

Digital twin use cases in Energy sector

The energy sector is undergoing a transformative shift, with a growing emphasis on renewable sources and sustainability.

Digital twins, as virtual replicas of physical systems, offer the energy industry a means to optimize operations, enhance efficiency, and drive innovation, all while ensuring environmental responsibility, illustrating the multifaceted benefits and applications of digital twins in advancing sustainable energy solutions.

35. Renewable Energy Optimization

Digital twins can simulate the performance of renewable energy sources like wind turbines and solar panels under various conditions. This helps in predicting energy output, optimizing placement, and ensuring maximum efficiency from these renewable sources.

36. Grid Management and Distribution

With the integration of renewable energy sources, managing the power grid becomes complex. Digital twins offer a real-time view of the grid, allowing for better load distribution, fault detection, and overall efficient energy management.

37. Energy Storage and Distribution

Digital twins can simulate energy storage solutions, such as batteries, to understand their performance, lifespan, and efficiency. This aids in optimizing energy storage strategies, ensuring a consistent power supply.

38. Energy Consumption Analysis

Digital twins of buildings or industrial complexes can monitor and analyze energy consumption patterns. This provides insights into potential energy-saving measures and promotes efficient energy use.

39. Enhancing Safety Protocols

The energy sector, given its critical nature, prioritizes safety. Digital twins can simulate various operational scenarios, helping operators understand potential hazards and devise safety measures accordingly.

40. Carbon Footprint Monitoring

With global emphasis on reducing carbon emissions, digital twins can monitor and analyze the carbon footprint of energy operations. This aids in devising strategies to minimize emissions and adhere to environmental standards.

41. Disaster Preparedness

In the event of natural disasters or unforeseen events, digital twins can simulate their impact on energy infrastructure. This helps in devising contingency plans and ensuring uninterrupted energy supply.

Construction, Engineering & Architecture

Use cases of Digital twin in Construction, Engineering & Architecture

The construction, engineering, and architecture industries are pillars of urban development and infrastructure growth. As these sectors evolve, the integration of digital twins is revolutionizing the way projects are conceptualized, designed, and executed.

By creating virtual replicas of physical structures and systems, digital twins offer a comprehensive view of projects, enabling real-time monitoring, optimization, and predictive insights, highlighting the transformative impact of digital twins in shaping the future of urban development and infrastructure.

Here, take a look at our comprehensive guide, where you understand the crucial role played by digital twins in construction.

Learn more about digital twins in the construction industry here.

42. Real-time Monitoring of Construction Sites

Construction sites are dynamic environments with multiple activities occurring simultaneously. Digital twins offer real-time monitoring capabilities, ensuring that construction progresses as per the planned schedule and design specifications.

43. Resource Optimization

Digital twins can simulate construction processes, helping project managers optimize resource allocation, reduce wastage, and ensure timely project completion.

44. Safety and Compliance

Safety is paramount in construction. Digital twins can simulate various scenarios, helping site managers understand potential hazards and implement safety measures. Additionally, they ensure that construction adheres to regulatory standards.

45. Environmental Impact Analysis

With a growing emphasis on sustainable construction, digital twins can simulate the environmental impact of projects. This aids in devising eco-friendly construction strategies and ensuring minimal environmental disruption.

46. Cost Estimation and Budgeting

Digital twins can provide detailed insights into construction processes, materials, and labor requirements. This aids in accurate cost estimation, ensuring projects remain within budget.

47. Integration with Building Information Modeling (BIM)

Digital twins seamlessly integrate with BIM, enhancing the capabilities of both. This synergy ensures detailed project documentation, enhanced collaboration, and efficient project execution.

Suggested Read: Digital Twin vs. Digital Thread

Maritime Industry

Use cases of Digital twin in Maritime industry

The maritime industry, with its vast expanse of operations ranging from shipbuilding to port management, is embracing the digital revolution. In this scenario, a notable example of a digital twin becomes evident as virtual copies of ships, ports, and maritime systems play a crucial role in transforming the sector.

They offer the maritime sector a comprehensive view of operations, enabling real-time monitoring, optimization, and predictive insights, demonstrating the extensive applicability and transformative potential of digital twins in enhancing maritime operations and management.

48. Port and Terminal Operations

Ports and terminals are hubs of activity. Digital twins offer real-time monitoring capabilities, ensuring smooth operations, optimizing cargo handling, and reducing turnaround times for ships.

49. Route Optimization

Digital twins can simulate various maritime routes, considering factors like weather conditions, currents, and potential hazards. This helps in selecting the most efficient and safe routes, reducing fuel consumption, and ensuring timely deliveries.

50. Cargo Management

Digital twins can provide detailed insights into cargo storage, handling, and transportation. This ensures optimal space utilization, reduces cargo damage, and ensures efficient loading and unloading operations.

51. Energy Efficiency

Fuel consumption is a significant concern in the maritime industry. Digital twins can monitor and analyze fuel consumption patterns, offering insights into potential energy-saving measures and promoting efficient operations.

52. Emission Monitoring

With increasing environmental regulations, digital twins can monitor and analyze the emissions from ships. This aids in devising strategies to minimize emissions and adhere to environmental standards.

53. Hull Performance Analysis

The performance of a ship's hull directly impacts its speed and fuel efficiency. Digital twins can simulate the performance of hull designs under various conditions, aiding in design optimization and ensuring optimal performance.


The explained digital twin use cases are 15 of the many to point out. And it spread across multiple industries, from healthcare to automotive and construction. What companies now need is a proficient team by their side to create, implement, and manage these digital twins. 

Yes, the tech is relatively new to many, and finding ideal candidates for an in-house team can be challenging. 

So what can you do? 

Partner with a tech expert. Research and reach out to digital twin development companies and choose the right one. Here is something you can look up to learn how to choose the right digital twin company for your business. 

Or, you can connect with the experts at Toobler. We can help you clear your doubts regarding digital twins and help you with further tech support.