News
18.06.26
Digital twins in product development: from CAD model to intelligent simulation
The complexity of modern products is increasing – and with it, the demands placed on development processes. Physical prototypes alone are no longer sufficient to cover all variants, stress scenarios and operating conditions. This is precisely where the digital twin comes in: as a virtual representation that combines geometry, physics and operational data in a single model.
For industrial companies, the Digital Twin is no longer a topic for the future. It is a practical tool that shortens development times, reduces prototyping costs and measurably improves product quality.
What distinguishes a digital twin from a CAD model?
A CAD model describes a product’s geometry – dimensions, tolerances and materials. The digital twin goes much further. It integrates simulation results, manufacturing information and, ideally, operational data from the field.
In practical terms, this means: Whilst a CAD model in NX shows what a component looks like, the Digital Twin also shows how it behaves under load, where thermal hotspots occur and how it ages. Simcenter provides the physical simulations, whilst Teamcenter links all the data within a single, integrated platform.
Three maturity levels of the digital twin
Geometric twin: This is based on a fully parameterised 3D model containing all relevant manufacturing information. Teamcenter ensures version control and data consistency. For many companies, this level of maturity represents the most realistic starting point.
Simulated twin: Building on the geometric model, simulation data completes the picture. Structural mechanics, thermal, flow and NVH analyses in Simcenter reveal the physical behaviour – long before a prototype exists.
Connected twin: At the highest level of implementation, sensor data from operational use feeds back into the model. Platforms such as MindSphere capture this data and enable comparisons between simulation and reality. This results in adaptive models that predict maintenance requirements and drive product improvements.
Tangible benefits: What are the advantages of the digital twin?
A medium-sized engineering firm that reduces the number of physical prototypes from three to one typically saves 60 per cent on prototyping costs and 25 per cent on development time. These are not theoretical figures – they are the actual figures companies achieve in practice.
Furthermore, the level of validation increases. Because virtual tests are faster and cheaper than physical ones, engineers can test more variants and load cases. The result: more robust products, fewer field failures and more satisfied customers.
The digital twin also offers opportunities in the area of sustainability. Material consumption, energy efficiency and recyclability can be assessed and optimised virtually – a growing competitive factor, particularly in the automotive and medical technology sectors.
Entry requirements
A digital twin does not require a budget running into millions. It requires a solid digital foundation and a clear plan.
End-to-end data management: Teamcenter, as the central PLM platform, ensures that CAD data, simulation results and bills of materials are consistent and version-controlled. Without this foundation, the digital twin remains a patchwork of individual files.
Integrated simulation tools: Simcenter, NX Nastran or partner solutions such as Altair must be seamlessly embedded in the development process. Isolated simulations, the results of which are sent by email, limit the benefits.
Expertise within the team: Applying simulation methods correctly and interpreting results accurately requires experience. Training and support from experienced partners accelerate the development of this expertise.
How the d.u.h.Group supports you
The path to a digital twin is unique to each organisation. It depends on your existing IT landscape, your products and your level of maturity in simulation. The d.u.h.Group supports you at every stage: from PLM implementation with Teamcenter, through simulation services with Simcenter, to training your teams.
With over 35 years’ experience as an authorised Siemens partner and project experience across more than 10 industries, we understand the typical hurdles – and the shortcuts. Together, we’ll develop a roadmap tailored to your business.
Talk to us about getting started with the Digital Twin.
Conclusion
The choice between Teamcenter and SAP PLM is not a question of which is better or worse. It is a question of focus. Companies with a strong engineering focus benefit from Teamcenter. Companies with an SAP-centred IT landscape will find SAP PLM a logical complement. And for many, combining both systems is the best approach.
The d.u.h.Group provides vendor-neutral advice based on your specific requirements. As an authorised Siemens partner, we know Teamcenter inside out – whilst also recognising where SAP is the better solution. Together, we’ll find the solution that suits your business.
Talk to us about your PLM strategy.
Topics
Technologies
Mehr entdecken