Visual Digital Twin

Enabling you to overlay digital content on the physical

Digital Twin

The Visual Digital Twin is an important element of the full Digital Twin, and it can be used on its own outside of a full Digital Twin process.

A full Digital Twin is a digital replica of a physical asset or entity. It aims to integrate IoT, artificial intelligence, machine learning, analytics, and a real time network. It includes the physical item, processes, people, systems and devices that can be used for various purposes. The digital representation provides both the elements and the dynamics of how an Internet of Things (IoT) device operates and lives throughout its lifecycle. There is a connection between the physical model and the corresponding virtual model, and this connection is established by generating real-time data using sensors.

The Visual Digital Twin enables a front line worker to see a rich 3D digital representation of the physical overlaid on top of the physical item, and can display related 2D text as well. This makes the job of understanding what needs “doing” on the physical very easy to understand and execute. The digital data can be displayed using a tablet, smartphone or Mixed Reality headset.


Visual Digital Twin

What Theorem-XR provides is a Visual Digital Twin Experience for HoloLens, a tablet or smartphone, which takes the 3D CAD representation and makes it available in any of the above devices. It also, via web services, enables the 3D representation to be linked to data coming from other sources, such as ERP, MES or analysed Sensor data.

As well as displaying the visual twin, the experience enables it to be snapped to, and correctly aligned, to the physical item. That means that a user looking at the physical has the digital 3D image correctly overlaid and orientated. This capability is very important for use cases such as inspection of the physical by comparing it to the digital. Or for a maintenance or assembly process where a front line worker is being aided (instructed) by a step by step process on the physical.

The Visual Digital Twin instantly informs a user of “differences” between the physical and digital, which is essential for quality inspection purposes. It is also essential to enable an operator to follow build or service instructions where by “assembling” or “disassembling” the digital, it quickly shows the operator what action has to be done on the physical item.

Understanding and interpreting large volumes of information in situ is greatly aided by the Visual Digital Twin. It therefore saves time and improves quality in inspection, product assembly and service functions.

Improve Product Understanding

By seeing your 3D digital design overlaid on top of the physical and using the digital to “disassemble” the physical speeds up the service or build process.

Locate Production Issues

During pre-production runs of new parts, compare new parts from the production line to their 3D CAD design to identify missing items, welds, and drill holes etc., enabling production issues to be quickly located and fixed.

Undertake Packaging Studies

Load new 3D digital versions of components on top of, or inside, the actual physical to establish fit, clash and access issues before finalising the design or production process.

Review Product Updates

When undertaking a product refresh or update, overlay the new digital “refreshed part” on to the existing physical to see if they look “right” and will fit.

Deliver Information

Information is more easily understood in context. By placing your text information linked to 3D data, and overlaying on the physical, the Visual Digital Twin improves understanding and saves time.

Compare your Product

To understand how your new product compares to a competitors existing physical product, overlay or position your Visual Digital Twin on top of, or next to, your competitors physical, and improve your product competitiveness.

Why Theorem Solutions?

Theorem Solutions is a totally independent company but with a strong and long standing business and technical relationship with Dassault Systemes, PTC and Siemens. These relationships enable us to develop products and solutions for the CATIA 3DEXPERIENCE, PTC and Siemens users.

With the use of Dassault Systemes strategic XCAD development tools and PTC and Siemens development API's always ensures full and ongoing compatibility, delivers high quality data and business benefits.


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