In a previous article on digital twins, we presented the basics of this innovative concept and explained how digital representations mirror the real world. In this article, we would like to take a step further and highlight the crucial role that continuous data streams play in this context, especially across the entire life cycle.

In recent years, the idea of the digital twin has evolved from a concept of the future to a key technology in industry, development and, increasingly, other sectors. Today, it serves as a central interface in the Internet of Things (IoT) between suppliers, manufacturers and end customers. The digital twin is therefore much more than a virtual model: it links data, processes and systems in real time, creating a dynamic image that evolves in parallel with physical reality.

Whether in product development, manufacturing, operation or recycling, digital mirroring ensures that information flows continuously and remains up to date at all times. However, this requires consistent data streams, precise models and a stable technical and organisational basis.

Consistent data flows as a key factor
Consistent data flows play a central role in this process. Whereas development departments, production, service and recycling often used to work with separate information systems and data was collected in silos, the digital twin breaks down these barriers. Thanks to networked systems, a continuous flow of information is created across all phases of the life cycle – from development and manufacturing to use and subsequent recycling.

These continuous data flows in the digital twin offer enormous advantages for both companies and society. They ensure more efficient workflows, as processes interlock more smoothly and the coordination effort between departments or project partners is reduced. At the same time, the constant availability of consistent data ensures higher quality by detecting errors earlier and avoiding rework. Flexibility also increases, as market and customer requirements can be implemented more quickly. In addition, digital twins make an important contribution to sustainability by promoting data-based decisions that conserve resources and specifically support the principles of the circular economy.

Challenges on the path to digital twins
As great as the potential of digital twins may be, their introduction is not a sure-fire success. Companies face a number of complex challenges relating to technical, economic and organisational aspects.

One key issue is the cost and investment involved. Setting up a digital twin requires considerable initial investment – for example, in sensors, IT infrastructure, data platforms and qualified specialist personnel. The return on investment (ROI) often only materialises in the medium to long term.

Complexity and scalability are also key issues. Especially when entire plants or production lines are to be digitally mapped, the effort required for modelling, data integration and maintenance increases significantly. Interdisciplinary expertise is needed here to build systems that are stable and future-proof.

Another challenge concerns interoperability and standardisation. The lack of standards between systems, device manufacturers and software platforms makes consistent data exchange difficult. Without clear interfaces and uniform data models, the potential of the digital twin often remains untapped.

In addition, data security and data protection are crucial factors. The close interconnection between the real and digital worlds creates new vulnerabilities – for example, in the protection of intellectual property or personal data. Clear security strategies and responsibilities are essential to ensure trust and stability.

Only those who address these challenges holistically can exploit the full potential of the digital twin in the long term.

The digital twin as a basis for innovation

In future, the digital twin will increasingly become a central component of Industry 4.0. By consistently using continuous data streams, companies can not only optimise their processes, but also develop new business models – from data-driven services to platform solutions along entire value chains.

However, the digital twin only reaches its full potential when data is not fragmented but seamlessly connected throughout the entire life cycle. This transforms a digital image into a living, strategic tool for efficiency, innovation and sustainability.