Digital Twin
Build a living digital replica of your factory. Simulate changes, validate decisions, and optimize operations — all without touching the physical line.
The IRIS Digital Twin module creates comprehensive digital representations of your physical assets, production lines, and processes. Every sensor reading, machine state, and process parameter is mirrored in real time — giving you a virtual factory that behaves exactly like the real one.
With 3D visualization powered by Unity and WebGL, operators and engineers can navigate an interactive model of the shop floor, inspect individual assets, and overlay live telemetry data. The simulation engine lets you run what-if scenarios — test a new production schedule, model a capacity increase, or validate a process change — and see the projected outcome before committing a single resource.
Digital twins also serve as the foundation for synthetic data generation, enabling AI model training without disrupting live operations. Combined with predictive analytics from the DATA_AI module, your digital twin becomes a decision-support engine that quantifies ROI before every investment.
Capabilities
Your Factory, Fully Digitized
From sensor ingestion to 3D simulation — everything you need to build, run, and optimize digital twins at scale.
Digital Twin Management
Create digital replicas of assets, production lines, and entire processes. Configure twin models, manage versions, define relationships, and track status across your facility.
Sensor Integration & Telemetry
Connect thousands of sensors and collect telemetry data at scale — up to 10,000+ events per second. Aggregate, store, and stream time-series data in real time.
Real-Time Synchronization
Keep digital twins in perfect sync with their physical counterparts via WebSocket connections. Bidirectional communication ensures changes flow both ways instantly.
3D Visualization & Unity
Render interactive 3D models of your factory floor with Unity and WebGL integration. Navigate scenes, inspect assets, and overlay live data on visual representations.
Simulation & What-If Scenarios
Run simulations with variable parameters to test production changes, capacity adjustments, or process optimizations — before committing resources in the real world.
Validation & Verification
Validate twin configurations, verify model behavior against real-world data, and generate validation reports. Ensure your digital twin accurately reflects physical reality.
Unified Dashboard & Analytics
Monitor all digital twins from a single dashboard with real-time metrics, historical trends, customizable widgets, and export capabilities for deeper analysis.
Alarms & Anomaly Detection
Configure threshold-based alarms and AI-driven anomaly detection. Get instant notifications when sensor readings deviate from expected patterns, with full escalation support.
Artificial Intelligence
Simulate the Future. Decide With Confidence.
Predictive Maintenance
AI models analyze sensor telemetry to predict equipment failures days or weeks in advance. Schedule maintenance at the optimal moment — not too early, not too late.
Synthetic Data Generation
Generate realistic training data for machine learning models by running simulations on your digital twin. No production disruption, no data privacy concerns.
ROI Validation
Before investing in new equipment or process changes, simulate the impact on throughput, quality, and cost. Get a projected ROI backed by your own operational data.
Anomaly Detection
Continuous AI monitoring of sensor streams detects deviations from normal behavior in real time. Surface issues before they cascade into downtime or quality defects.
See It in Action
Navigate an interactive 3D model of your factory floor with live sensor overlays, real-time status indicators, and simulation controls.
Integrations
The Digital Thread Across Your Operation
Digital Twin connects to every layer of the IRIS platform — from shop-floor sensors to AI models — creating a unified digital thread.
MES
Mirror production lines and processes for real-time monitoring and simulation.
CMMS
Link asset twins to maintenance records for predictive maintenance modeling.
QMS
Overlay quality data on digital twins to visualize defect patterns spatially.
HSE
Integrate safety and environmental data for risk-aware simulations.
IoT
Ingest sensor telemetry from the IoT layer to feed digital twin state in real time.
DATA_AI
Power predictive models, anomaly detection, and optimization recommendations.
Build your digital factory today
See how IRIS Digital Twin lets you simulate, validate, and optimize — turning your physical operations into a competitive advantage.