Digital twin & virtual
commissioning
We develop digital twins of plants and equipment, accelerating design, testing, validation, and industrial commissioning.
What is a digital twin?
The industrial Digital Twin is the digital replica of a machine or system, continuously fed by real-world data. It evolves over time alongside its physical counterpart , allowing for failure prediction, performance optimization, and product support from design to after-sales service. Virtual Commissioning represents the initial and most limited phase: it involves testing the machine's control software on a virtual model before it even physically exists, anticipating errors at no cost and drastically reducing commissioning times in the workshop.
Why develop a digital twin?
The integration of digital technologies into production processes is no longer a trend, it is an essential condition for remaining competitive.
Benefits along the Value Chain
One of the most relevant aspects is the ability to generate value in multiple phases of the product life cycle.
Engineering
The engineering department can develop and validate machine code in parallel with mechanical and electrical design. Design errors are identified and corrected early, before production.
Marketing & Sales
The virtual model becomes an immersive presentation tool: prototypes, large lines, process flows not visible to the naked eye or at high speeds can be shown to the customer with full-scale experiences.
After sales
For after-sales, the virtual model is the foundation for making operator training processes more efficient and safe. Furthermore, by integrating IIoT and AI, it is possible to enable predictive maintenance and continuous performance optimization services through simulation and testing on the digital twin.
The areas of application of the digital twin
Automation
Machine & PLC
Development and validation of PLC software and automation logic.
Training
Operator & HMI
Training of technicians for on-board machine operations.
Operations
Production plant
Optimize production processes, logistics, and asset management using an AI-based orchestrator.
Physical AI
AGV & Humanoid
Training in AI technologies underlying the integration of new automation systems such as AGVs and humanoid robots.
Digital twin & Physical AI to enable the autonomous factory
Connected to the real plant, the AI in the digital twin monitors the system's status, simulates scenarios, and optimizes production flows and assets in real time.
AI-powered orchestrator
The plant's digital twin becomes the virtual gym where artificial intelligence takes shape: here, AI models train, learn to manage every scenario, and arrive ready for the real plant, risk-free and without losing control.
Physical AI
With Physical AI, artificial intelligence learns to navigate the physical world. In the plant's digital twin, humanoid robots are trained to collaborate side by side with people, acquiring the necessary skills to operate safely in the real factory in the virtual field.
Want to learn more?
Genesi: The Platform for Digital Twins and Physical AI
Genesi is the platform developed by Applied to create Digital Twins of machines and systems, with real data, interactive physics, and integrated IoT technologies. It was designed to be flexible and scalable: it connects to multi-brand control systems and supports the product throughout its entire life cycle, from testing to after-sales service.
Its evolution stands out for the synergistic integration of artificial intelligence, virtual/augmented reality, and motion tracking technologies into a single platform, designed to be accessible even to those without specialized simulation skills.
An approach that makes simulation simpler, smarter, and more results-oriented, improving ergonomics, training, and decision-making processes.
Our technology partnership
Our technology partnership
Our team
One team, multiple skills: Applied's Digital Engineering group brings together specialists from different disciplines to turn digital innovation into concrete results for your industrial projects.
Multidisciplinary collaboration: each specialist's expertise comes together in true teamwork, ensuring more complete and consistent solutions at every stage of the project.
Multi-brand specialist skills: mastery of multiple software stacks and technology platforms, so we can always choose the tool best suited to the job, with no vendor lock-in.
Integration with OEM teams: the ability to embed within the customer's design and R&D processes, working side by side with their technical teams.
A single point of contact: one reference point to turn innovative projects into reality, from design through to commissioning.