A digital twin, powered by analytics and simulations, is a virtual counterpart of a real-world asset. It replicates the behavior and lifecycle of the physical asset through integrated multidomain system simulations. Hybrid digital twins facilitate system design, predictive maintenance, and enhance industrial asset management. Utilizing Ansys Twin Builder can enhance revenue generation, cost management, and help sustain a competitive edge.
ANSYS DIGITAL TWIN RESOURCES & EVENTS
A step-by-step guide to creating, validating, and exporting digital twins using Ansys Twin Builder — covering model assembly, ROM generation, and sensor data fusion for industrial asset monitoring.
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This paper covers ROM creation workflows in Ansys Twin Builder, comparing SVD-based and machine learning ROM techniques for structural, thermal, and fluid applications in edge-deployed digital twins.
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Explore how to combine Ansys simulation data with operational sensor streams to train robust predictive maintenance models — overcoming data scarcity and improving remaining useful life estimates for rotating machinery.
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Ansys TwinAI is an AI-augmented, simulation-based digital twin platform designed to validate digital twin models within environments typically found in cloud infrastructures, which include simulation engines, operating systems, and data streams. This platform offers various capabilities, primarily allowing users to simulate their created digital twins, enhance the accuracy of these digital twins through Hybrid Analytics, and simplify and streamline their deployment process.
Ansys Twin Builder enables quick digital twin creation, enhancing lifecycle management, predictive maintenance, and cost savings.
Combining physics and data modeling to enable real-time monitoring, predictive maintenance, and performance optimization.
An integrated solution for BMS development that allows for risk-free virtual testing.
Comprehensive wind turbine simulation, from embedded software to sizing, predictive maintenance and digital twins.
Power electronics systems are complex. Simulation provides the tools to efficiently solve high-level design challenges, improve performance and drive innovation.
Full system integration from the concept design stages to analysis optimization and verification.
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Optimal heat exchanger design for performance and energy efficiency, material selection, durability and life prediction under harsh conditions.
Ansys offers state-of-the-art software to help design a wide variety of rotating machinery equipment. Whether you are developing fans, pumps, compressors or turbines, Ansys simulation software allows you to quickly iterate and improve on designs.
A digital twin is a virtual replica of a physical asset, system, or process that is continuously updated with real-world operational data. It combines physics-based simulation with live sensor inputs to mirror the current state of its physical counterpart and support predictive decision-making.
Ansys Twin Builder is a multi-domain system simulation platform that enables engineers to create, validate, and deploy physics-based digital twins. It combines ROM technology, machine learning, and real-time IoT data integration to build operational twins that run in industrial deployment environments without requiring Ansys licences on the target hardware.
Digital twins continuously compare live sensor data against physics-model predictions to detect deviations that indicate degradation or developing faults. By tracking accumulated damage and remaining useful life in real time, they enable maintenance to be scheduled based on actual asset condition rather than fixed intervals — reducing both unplanned downtime and unnecessary servicing.
A reduced-order model compresses a high-fidelity simulation — such as an FEA or CFD model — into a compact mathematical representation that reproduces the same physics at a fraction of the computational cost. ROMs are essential for digital twin deployment because they allow rigorous physics to run in real time on edge or cloud hardware.
Ansys Twin Builder exports digital twins as portable runtime packages with standard REST API interfaces. These runtimes can be connected to industrial IoT platforms — such as AWS IoT, Azure Digital Twins, or PTC ThingWorx — to receive live sensor data streams and return updated state estimates, predictions, and recommendations through the same interface.
Digital twins deliver the greatest value in industries with complex, high-value, or safety-critical assets — including energy and utilities, aerospace and defence, automotive and EV, industrial machinery, and semiconductor manufacturing. Any sector where unplanned downtime is costly or where continuous performance optimisation drives competitive advantage can benefit from digital twin technology.
Whether you're solving complex engineering challenges, accelerating innovation, or exploring new possibilities with simulation and digital engineering, our team is ready to support you. Backed by deep technical expertise and industry experience, we work closely with organizations to transform ideas into reliable, high-performance solutions. Connect with us to discover how CADFEM can help drive your next breakthrough.
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