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Digital twins, simulation, and robot offline programming help manufacturers design, test, and optimize production systems in a virtual environment before they are implemented on the shop floor. In this FAQ, we answer some of the most common questions about digital twins, simulation, and modern engineering processes in manufacturing.
A digital twin is a virtual representation of a real-world system, such as a robot cell, machine, production line, or even an entire factory.
Unlike a standalone 3D model, a digital twin enables manufacturers to simulate, analyze, and optimize processes in a virtual environment. This makes it possible to test, validate, and improve production systems before they are deployed.
Manufacturing systems are becoming increasingly complex. Robots, autonomous mobile robots (AMRs), AGVs, software, control systems, and material flows are more interconnected than ever.
Digital twins help manufacturers:
As a result, analysts expect continued growth in the digital twin market in the years ahead.
As KUKA Group CEO Christoph Schell notes: "Simulation is no longer an optional engineering tool – it is a strategic capability." This shift reflects the growing role of simulation and digital twins in helping manufacturers manage complexity and make better decisions throughout the lifecycle of a production system.
A digital twin for a robotic system creates a virtual representation of a robot cell, including robots, workpieces, grippers, fixtures, and process logic.
This allows manufacturers to:
before a physical robot is programmed or installed.
Simulation creates a virtual model of a process or system and allows different scenarios to be tested.
A digital twin goes one step further by creating a connection between the physical and digital worlds, enabling the ongoing analysis and optimization of real production systems.
In simple terms:
Many manufacturers choose to modernize existing production facilities rather than build new ones.
Digital twins make it possible to test and validate planned changes before implementation. This can help reduce risk and provide better visibility into how changes may affect ongoing production.
As a result, simulation and virtual commissioning can support a more predictable retrofit process.
Digital twins are no longer limited to large manufacturing operations.
They can also provide value for small and mid-sized manufacturers, particularly as production systems become more complex, product variation increases, or modifications to existing facilities are planned.
Read our case study to learn how HASE Kaminofenbau GmbH uses digital twin technology and KUKA welding robots to increase efficiency and scale production to meet growing demand.
End-to-end automation brings together planning, engineering, robotics, simulation, virtual commissioning, and optimization across the entire lifecycle of a production system.
Digital twins provide a common foundation for:
This helps create connected digital workflows rather than isolated processes.
In the context of Automation 2.0, automation systems are increasingly viewed as connected ecosystems rather than collections of individual machines, robots, or software tools. The focus shifts to the entire lifecycle of a production system.
Digital twins support this approach by providing a virtual representation of production systems that can be used from the earliest planning stages onward. Simulation, offline programming, and virtual commissioning become part of a continuous digital workflow.
By helping manufacturers manage complexity and connect engineering, automation, and continuous optimization, digital twins support key principles of Automation 2.0.
Offline Programming (OLP) refers to creating and optimizing robot programs in a virtual environment.
Instead of programming robots directly on the shop floor, robot paths and process sequences are first simulated and validated virtually. The programs are then transferred to the physical system.
This approach can help reduce production interruptions and streamline project execution.
Robot simulation allows manufacturers to validate production systems early in the project lifecycle.
Common applications include:
This can help reduce risk and support more informed engineering decisions.
Offline robot programming can help manufacturers:
In dynamic manufacturing environments, offline robot programming is becoming an increasingly important part of modern automation.
Virtual commissioning involves testing robot programs, PLCs, and production processes before physical commissioning begins.
This allows manufacturers to verify how system components interact within a virtual environment.
Virtual commissioning can help:
iiQWorks is KUKA’s engineering suite for digital manufacturing. Combined with the iiQKA.OS2 operating system, it provides the foundation for end-to-end digital engineering, covering everything from configuration and the creation and use of digital twins to robot simulation, offline programming, and virtual commissioning. A seamless flow of data across all engineering stages simplifies planning, reduces potential sources of error, and accelerates the implementation of automation projects.
A key component of the suite is iiQWorks.Sim. The simulation software enables the virtual planning, simulation, and optimization of robotic applications using digital twins. This allows processes to be tested, validated, and optimized before physical commissioning, increasing planning reliability and reducing investment risk.
The suite is further enhanced by the iiQWorks Copilot, which supports engineering teams with AI-powered assistance. Engineers can find information more quickly and complete engineering tasks more efficiently. In addition, the iiQWorks AppBuilder enables users to create custom applications for specific automation requirements and flexibly extend existing workflows.
Companies benefit from an integrated engineering platform, seamless data flow between planning, simulation, and production, shorter project timelines, and faster, more reliable commissioning. In this way, iiQWorks helps manufacturers move toward a more efficient, transparent, and cost-effective digital production environment.
Key benefits at a glance:
Visual Components, part of the KUKA Group, offers software solutions for:
If you're ready to explore how simulation and virtual commissioning can bring new life to your operations.
Visual Components 5.1 was developed to address the growing complexity of modern manufacturing environments.
According to Mika Anttila, CTO of Visual Components:
“Manufacturers are under increasing pressure to deploy more autonomous and flexible production systems, but the complexity of those environments is growing faster than many existing tools can handle. Our customers need to validate how hundreds of moving resources, robots, vehicles, products, and people interact before anything is installed on the factory floor. With 5.1, we’re giving them a much more scalable and realistic way to do that.”
Key enhancements include:
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As Mikko Urho, CEO of Visual Components, explains: “Manufacturing environments are becoming increasingly dynamic. Mobile robots, automation, and connected production systems create new opportunities, but also new complexity. Before making investments or changes on the factory floor, manufacturers need confidence that their plans will work in practice. Visual Components 5.1 allows manufacturers to validate complex operations earlier in the planning process, reducing risk before deployment.” |
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Automation is becoming increasingly software-defined. As a result, manufacturers are moving more planning, engineering, and optimization activities into the digital world.
The more complex production systems become, the more important it becomes to understand, validate, and optimize them before implementation. As a result, digital twins are evolving from an engineering tool into a strategic foundation for modern manufacturing.
