Flying into the Future with Virtual Twins in Manufacturing
When global trade shifts and tariff battles reshape the playing field, manufacturers often find themselves under immense pressure. To explore how digital innovation can turn uncertainty into opportunity, we spoke with Buddharatn Ratawal, Senior Manager of Strategic Business Development for DELMIA at Dassault Systèmes.
As an expert in virtual twin technology, Ratawal shared insights on how manufacturers are using digital replicas of their factories to transform capital planning, operational efficiency, and long-term resilience.
Rethinking Capital Investment
We began by asking the critical question on every manufacturer’s mind: What is the capital investment required to expand or build new manufacturing capacity?
Ratawal responded: “To answer that question accurately, you need a Virtual Twin of your production systems. It’s the only way to see what new or modified facilities and processes should look like before you invest. The twin helps companies make informed decisions rather than relying on risky guesses.”
According to him, knowing how much a new or expanded plant will really cost depends on the ability to picture it in full detail. The DELMIA Industrial Engineering software makes this possible by consolidating existing digital assets, drawings, CAD models, bills of material, into a living, three-dimensional replica of the factory. The outcome is a virtual environment where managers can evaluate processes, equipment, and workflows long before the first brick is laid.
Walking Through the Factory Before It Exists
We asked how this technology changes the planning process. Ratawal explained: “With the virtual twin in place, teams can fly through the factory before it exists, test different layouts, and watch the flow of parts, people, and robots. This allows you to spot where space, time or energy will be wasted.”
This level of foresight helps reduce inefficiencies before they materialise. By making adjustments early, businesses cut down on waste, improve robot uptime, and avoid costly mistakes. Ratawal was keen to stress that this approach doesn’t just refine operations; it transforms a risky capital gamble into a confident, data-driven business plan.
A Step-by-Step Guide to Virtual Twin Planning
Ratawal walked us through the process of creating and applying a virtual twin using DELMIA. The steps include:
- Consolidate All Data – Integrate 2D drawings, CAD models, bills of material and point-cloud scans into one shared platform.
- Process Engineering – Convert engineering service BOM software into an MBOM, sequence operations, assign resources, and generate work instructions.
- Machining & Additive – Simulate NC toolpaths or additive layers directly on the twin, validating quality and spindle loads.
- Virtual Factory & Flow – Lay out machines and conveyors in 3D, then run flow simulations to identify throughput and bottlenecks.
- Robotics & Automation – Add any of 2,000+ robot models, generate collision-free paths, and optimise cycle time and energy use.
- Ergonomics & Safety – Evaluate manual tasks, verifying safe distances between people, AGVs, and robots.
- Virtual Commissioning & Go-Live – Integrate real PLC or robot code into the model, debug logic, and train operators virtually.
- Continuous Optimisation – Stream MES/IoT data back into the twin to monitor OEE and run fresh “what-if” scenarios.
Turning Data into a Living Factory Model
Asked why this approach is so transformative, Ratawal noted: “The twin consolidates scattered engineering assets into one living model. By the time the first robot is ordered, or cancelled, you’ve already stress-tested multiple scenarios and locked in a configuration that maximises efficiency from day one.”
Manufacturers using virtual twins gain a competitive edge by testing tariff, wage, and logistics variations in hours rather than weeks. This level of agility makes companies more resilient when regulations or trade rules shift suddenly.
A Case Study in Resilience
One standout example comes from Shanghai-based CNBM Triumph Robotics, a DELMIA client. Ratawal highlighted their success: “By using the 3DEXPERIENCE platform, Triumph Robotics cut delivery time by 30% while also reducing costs. They eliminated inefficiencies, reduced labour overhead, and improved quality through early digital testing.”
The case underscores how virtual twins do more than improve planning, they strengthen the bottom line while speeding up time-to-market.
The Broader Benefits for Manufacturers
Virtual twins are not just about risk reduction. They create opportunities for continuous improvement and sustainability. By streaming real-time data back into the twin, manufacturers can:
- Monitor energy use and emissions.
- Adjust production processes to minimise waste.
- Adapt quickly to changes in demand or supply chain disruption.
In industries where margins are tight and regulatory landscapes evolve quickly, these capabilities can be the difference between thriving and struggling.
Building the Resilience for Tomorrow
Ratawal concluded with an optimistic note: “Virtual twin technology isn’t just about efficiency today. It’s about building the resilience needed for tomorrow. Companies that embrace it will not only cut costs but also respond faster to change and deliver better outcomes for customers.”
Manufacturers navigating tariff turbulence and global uncertainty have a new tool at their disposal. By investing in virtual twins, they’re no longer making blind bets. Instead, they’re building smarter, stronger, and more resilient businesses that can withstand the shocks of global trade.
