Revolutionizing the machinery and robotics industry: an insider’s view of Unity and the reality of digital twins
Thomas Strigl has 18+ years of experience in creating and distributing simulation and commissioning software solutions. He recognizes that the modern robotics and machinery industry requires innovative solutions. This is why Thomas founded realvirtual.io in 2018, with the aim to pursue opportunities to embrace gaming technology to solve the challenges of complex automation systems. In this article, Thomas shares his thoughts on Unity’s place in the industry - and the importance of digital twins.My vision for digital twins in industryThe machinery and robotics industry is rapidly evolving, driven by digital transformation. Of course, we can’t ignore the elephant in the room: “digital twin”. The term has become a buzzword, tossed around in marketing campaigns and industry conferences. While the concept holds incredible potential, I believe it’s essential to go beyond the hype and focus on tangible, real-world applications.Digital twins are revolutionizing how production and factory operations are planned, monitored, and optimized. My vision is to fully realize their potential by integrating them seamlessly across every stage of the manufacturing lifecycle, from initial engineering design to real-time operations.Central to this vision is the synchronization of digital twins with engineering planning tools, such as CAD systems and electrical and automation design software. By ensuring that digital twins are updated in real time as changes occur in these tools, factories can maintain a continuous, accurate representation of their assets and processes. This creates a closed-loop system where design and operational data flow seamlessly, bridging the gap between planning and execution.Combined with 3D visualization and real-time human-machine interfaces (HMIs), digital twins provide an intuitive way for operators and engineers to interact with live production environments. Through robust industrial communication standards like OPC UA, MQTT, and Profinet, these twins integrate with real-world systems to create “digital shadows” that mirror ongoing operations.This real-time synergy between design, engineering, and production empowers factories to optimize workflows, reduce errors, and adapt to changes faster. The result is a smarter, more connected factory environment that drives efficiency, agility, and innovation.Uses for real-time solutions in robotics and machineryThe real-time environment is a powerful solution for the challenges faced in machinery and robotics, enabling teams to create applications for a broad range of use cases, such as:Design validation: Create high-fidelity simulations to test designs before physical production. This reduces errors, shortens development cycles, and improves final outcomes.Virtual commissioning: Engineers can simulate and test the logic of machine controls in a virtual environment, avoiding costly delays and errors during physical setup. For example, by connecting a real-world robot and PLC controllers to a digital model.3D human-machine interfaces (HMI): Create interactive and intuitive HMIs, making machinery easier for operators to control and understand.Vision AI training: Simulate real-world camera frames, perform synthetic data annotation, and train vision AI algorithms, especially for robotics systems.Stakeholder communication: Create immersive visualizations or VR experiences that make complex ideas understandable to non-technical stakeholders.Where realvirtual.io fits inSpecialized tools like realvirtual.io build on real-time capabilities to cater specifically to the machinery and robotics industry. Available as an add-on asset, realvirtual.io provides a set of tailored tools for creating digital twins that go beyond visualization.With these tools, users can:define kinematics for complex machineryadd virtual drives and sensorsinterface with real robot controllers or PLCs for virtual commissioningcreate 3D HMIsrun simulations that mimic the behavior of physical machinesDigital twins also play a vital role in training convolutional neural networks (CNNs) for industrial vision applications. By generating synthetic, highly realistic datasets in simulated environments, they enable AI systems to learn complex recognition and decision-making tasks efficiently, before the real products or production even exist, speeding deployment and improving accuracy in real-world conditions.To streamline this process, our new product AI Builder simplifies the creation of advanced AI-ready digital twins and supports AI training directly within Unity’s ecosystem, making it easier than ever to deploy AI based industrial applications.My opinion: Unity as the future of digital twinsThe promise of digital twins is exciting, but I believe it’s critical to remain grounded. While flashy terms generate buzz, it’s the practical applications that truly drive value.In my experience, Unity’s power lies in its ability to enable teams to create solutions that address real problems, from improving design, to enhancing communication, or reducing commissioning errors. Introducing a new idea, interface, or user interaction is so much more straightforward when using the open development ecosystem and open source code of Realvirtual.io. You can see results fast without the need to wait for long software release cycles.Unity stands out because it is both powerful and accessible. Its real-time rendering capabilities, robust ecosystem, and adaptability make it ideal for solving real-world problems in machinery and robotics. What makes it particularly valuable is its modularity, openness, and ecosystem—an endless array of tools and extensions available through the Unity Asset Store and its Package Manager, many of which were originally created for gaming but translate seamlessly into industrial applications.Here’s one game-changing fact that sets Unity apart: it enables you to build and deliver applications to almost any platform, with no need for cloud rendering. This means you can create a digital twin and deploy it in multiple ways, such as:Mobile app for on-the-go use.Desktop applications for Windows, Linux, or macOS.Immersive experience on Meta Quest or other VR/AR devices.WebGL-based solution accessible directly through a browser.Let’s start a conversationI’d love to hear your thoughts. Are you leveraging Unity in your machinery or robotics projects? What challenges are you tackling, and how do you see digital twins evolving? Please share your experiences—I’m always eager to learn from others in this exciting field.This article reflects my personal insights and experiences working with Unity and digital twin technologies. Let’s focus on what really matters: delivering results that transform how we design, build, and operate machinery in the modern age.
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