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Digital Twin

Get it right the first time in part manufacturing

In CNC manufacturing, getting it right the first time is key to precision, efficiency, and cost control. A central lever for this: integrating the real and digital worlds to turn ideas into high-quality parts without costly iterations.

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SINUMERIK 828D 5th Gen Digital Twin

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What challenges do you face in part manufacturing?

To improve your part manufacturing, focus on the specific challenges and requirements unique to your industry use case. Each industry has its own considerations and solutions, so tailoring your approach can lead to better results.

CNC lathe machining a cylindrical metal workpiece, with coolant spray and cutting tools in action

High variability: CNC in a job shop

Small manufacturing shops producing simplified or custom parts often face tight margins and high variability. Programming directly on the machine – without advanced CAM tools – leaves little room for error and increases the risk of crashes, incorrect offsets, or costly downtimes. At the same time, finding qualified personnel, training on various interfaces, and integrating new technology can pose real challenges.

A Digital Twin offers a future-proof solution: it enables NC programs to be developed, tested, and optimized virtually – without interrupting operations. This boosts efficiency, reduces errors, and ensures first-time-right machining even in high-mix, small-batch environments.

Complex workpieces for high-precision manufacturing ​

Manufacturers face growing challenges from precision demands and strict quality standards. Long cycle times, low volumes, and complex, customized parts strain operations. Limited real-time visibility, frequent downtimes, and trial-and-error optimization drive inefficiencies and costs. Ensuring consistent quality and training staff on new tools adds complexity, while mistakes can delay production and lead to costly rework.

A Digital Twin ensures a perfect match between the virtual and real machine - essential for high-precision parts and crash prevention. It enables virtual testing and validation of NC programs created in the CAD environment, enhancing precision, reducing errors, and optimizing operations.

CNC milling of a turbine blade disc, with a drill bit cutting into the precision-machined metal component.
CNC milling machine cutting a circular metal workpiece, with metal chips and coolant spray flying during high-speed machining

Complex machining operations in a mass production

In high-volume production, every second counts. Complex machining must run efficiently and at scale - without compromising precision. Initial part programming and testing are critical, as errors can lead to delays, waste, and higher costs. High automation levels demand seamless technology integration and well-trained teams to ensure consistency and output.

A Digital Twin simulates and validates the machining process virtually, ensuring accuracy and optimizing parameters before production. This reduces errors, ensures quality standards, and minimizes downtime—ultimately enhancing efficiency and precision in manufacturing. Newly designed tools can also be tested for cycle time reduction.

What is a Digital Twin, and why do you need it?​

A CNC Digital Twin is a digital replica of the entire CNC system, accurately reflecting its control logic, kinematics, and behavior. This digital representation enables comprehensive simulation, analysis, and optimization of the system performance in a virtual environment - any real-world changes are made. It ensures precision from the very first part, reduces downtime, and increases overall efficiency.

Key benefits

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Faster time-to-market​

Digital Twins accelerate the development and validation of new products and processes. By simulating and optimizing designs virtually, manufacturers can bring products to market faster - gaining a competitive edge.

Icon representing cost savings: a clock with a dollar sign

Cost savings​

The ability to optimize machining processes and prevent errors before they occur lowers costs significantky. Reduced scrap rates, minimized tool wear, and efficient use of materials all contribute to lower operational costs.

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Improved quality control​

By simulating and analyzing machining processes virtually, Digital Twins help ensure the final product meets strict quality standards. This reduces defects and rework - and higher customer satisfaction and lower production costs.

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Seamless workflow integration​

Digital Twins streamline the shift from digital to real-world machining, cutting setup time and boosting productivity. They ensure precision and reliability through continuous safety checks from simulation to execution.

Where can you use a Digital Twin in manufacturing?

Digital Twin technology transforms how manufacturers achieve precision, productivity and efficiency. By bridging the digital and the real world, it enables a smarter, more flexible way to prepare, test and improve machining processes – long before manufacturing operations begin.

Virtual job preparation

Machining jobs can be virtually prepared and planned before production begins - including machine setup, tool selection, and parameter definition - all done offline on a PC. Multiple machine twins can be stored on a single computer, allowing NC programs to be created from one workstation. Ready-to-run programs are transferred directly to the real machine, reducing setup time by up to 20%. Users can prepare and test NC programs and train employees even while waiting for new machines - ensuring full readiness when they arrive.

engineer working at a dual-monitor workstation.
CNC operator working with a digital twin simulation on a dual-monitor workstation

Offline programming and validation

CNC programs can be created and tested offline, without interrupting actual machine operation. NC programs are developed and validated on a PC, allowing testing and optimization to take place entirely in the virtual space. This approach significantly reduces downtime and cuts unproductive machine time by up to 75% - while also improving process reliability and efficiency.

Simulation (basic and advanced)​

Users benefit from both basic and detailed simulation capabilities. Basic simulations quickly reveal potential issues, while advanced simulations offer deeper insights and enable process optimization. By integrating control and kinematics data from VCP files with CAM capabilities, users gain access to a precise simulation environment. This allows them to check manufacturability, assess machine suitability, and accurately calculate production time - without investing in real machines or production capacity.

Engineer reviewing a CNC toolpath simulation
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Training and skill development

Operators can be safely trained on virtual machines, handling various scenarios and programming tasks without risking equipment or interrupting production. Mistakes can be corrected immediately, and training can take place before machines are delivered. This reduces errors, eliminates the need for physical prototypes, and keeps machines available for actual production.

What solutions does Siemens offer me, including partner collaborations?

Siemens offers a comprehensive suite of Digital Twin solutions designed to address these challenges, enhancing efficiency, accuracy, and safety in CNC machining operations. Here are the key solutions Siemens provides, including collaborations with partners.

From virtual machining to first-time-right production

Run MyVirtual Machine is the Digital Twin of a Siemens CNC controller, specifically the SINUMERIK ONE and the SINUMERIK 828D. It offers numerous benefits, including the ability to create, validate, and optimize NC programs offline on a PC. It also serves as an excellent platform for training and further education.

  • 1:1 Digital Twin of CNC controller: Run real NC code in a simulated environment before executing it on the actual machine.
  • Standalone solution for job shops: Mirrors the SINUMERIK CNC interface, enabling offline validation of tool movements and setups.
  • Optional integration with NX CAM: Ensures a perfect match between CAM-generated toolpaths and real machining execution, improving accuracy and reducing material waste.
Run MyVirtual Machine software interface showing the SINUMERIK operator panel alongside a 3D turning simulation
3D simulation of a CNC machining center with collision detection active, showing a workpiece setup on a rotary table

From collision risks to collision-free machining

Protect MyMachine /3D Twin is a real-time collision prevention system that continuously monitors the machining process to detect and prevent potential collisions. It uses the same 3D engine as Run MyVirtual Machine, ensuring seamless integration and consistent safety from virtual simulation to real-world execution. This system safeguards both the machine and the workpiece - making it especially valuable in fast-paced environments and high-precision manufacturing.

From 3D CAD models to CNC programs in minutes

Optimize MyMachining /3D Scanner reduces programming time and improves product quality by minimizing errors. The smart analysis algorithm captures actual part geometry and suggests optimized machining strategies based on geometric features. This saves time and costs, prevents programming errors, and ensures consistent quality. Available as a perpetual license for real machines and as an option for their Digital Twin via Run MyVirtual Machine. More information

Optimize MyMachining /3D Scanner
Run MyVirtual Machine /3D Screenshot from application

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Integrated CNC machine and machine tool Digital Twins

CNC machine tool paired with its digital twin wireframe rendering on dark background

Siemens collaborates closely with leading CNC machine OEMs to develop joint solutions. End users gain substantial benefits from the joint offer, which combines the Digital Twin of a CNC controller with the Digital Twin of a machine tool.

This integrated solution enhances efficiency, accuracy, and productivity in CNC machining operations. This unique offering delivers significant benefits:

  • Seamless integration of virtual and real machines – from machine logic to HMI
  • Unified support from Siemens and the machine builder
  • Cost and time savings through faster commissioning, fewer errors, and shorter training times

Digital Twin solutions in action

The joint offering merges the Siemens CNC Digital Twin with high-fidelity machine tool Digital Twins from OEMs. Since these models are applied by the OEMs in their own operations, they reflect real machine behavior and enable accurate programming, simulation, and process optimization from day one. From machine tool development and commissioning to production and service, these real-world examples demonstrate the value of integrated CNC and machine tool Digital Twin solutions.

Frequently asked questions