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Digital Twins in Action MEAP V04 (Greg Biegel)(Z-Library)

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Technology
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Build a living digital replica of your real-world systems! A digital twin is a software-based replica of a physical system that can be used to operate, monitor, and maintain it remotely. Working together, IoT sensors, 3D visualizations, simulation algorithms, AI models, and even robotics give a digital twin an impressive degree of control. This virtual environment is perfect for testing ideas, exploring "what if" scenarios, and unlocking insights—all without making costly changes in reality. Digital Twins in Action teaches you how to: Define clear business objectives for digital twins Create digital representations of physical systems Blend computer vision, OCR, and generative AI with 3D geometric models Stream IoT sensor data into a twin Represent real-world systems as knowledge graphs Machine learning and agentic AI for analysis and decision-making Author Greg Biegel has developed numerous industry-scale digital twin platforms from the ground up. In Digital Twins in Action, he shares this unique experience with real-world insights about state of the art digital twins you can put into action today. There’s no niche academic theory—just a complete, practical introduction to every layer of the digital twin stack.

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MEAP Edition Manning Early Access Program Digital Twins in Action Version 4 Copyright 2026 Manning Publications For more information on this and other Manning titles go to manning.com. © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Welcome Thank you for purchasing the MEAP for Digital Twins in Action. Digital twins have been a hot topic for several years now and there is a lot of excitement, interest, and opportunity in the field. A lot of this is because the technology that enables you to build a digital twin has become accessible to just about anyone now, opening up endless possibilities for innovation. Despite all the buzz, there’s surprisingly little practical guidance available. Google "digital twins" and you’ll find countless glossy brochures, white papers, and marketing materials filled with futuristic 3D renderings but often lacking real substance. When you try to go deeper, you quickly discover there’s no comprehensive, practical guide explaining what a digital twin actually is and, more importantly, how you can build one yourself. This gap isn’t surprising. Unlike well-established technologies like the Java programming language or relational databases which have dozens of excellent books dedicated to them, a digital twin isn’t a single technology but rather a system integrating multiple advanced disciplines: the Internet of Things, computer graphics, databases, artificial intelligence, and machine learning, each complex enough to warrant its own book. I’ll admit it’s a bit of a cliche, but I’ve genuinely tried to create the book I wish I’d had when starting my digital twin journey. You’ll explore all the essential topics for building a digital representation of a physical system—from creating a simple sensor to measure real- world changes, all the way through programming an AI agent to make autonomous decisions. I’ll provide practical examples throughout and take you along as I build a digital twin of my own home. While you’ll need some familiarity with Python to follow the practical examples, and TypeScript for the frontend components, I believe you’ll gain valuable insights even if you choose not to follow every line of code! I primarily use AWS for cloud services, but I’ll explore other providers whenever they offer compelling alternatives. Your feedback is crucial to making this the best book possible, and I encourage you to share your thoughts in the liveBook Discussion Forum. I’m genuinely excited to hear your perspectives and answer any questions as we build this resource together. Thanks again for your interest and trust in purchasing the MEAP! -Greg Biegel © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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brief contents 1 Bridging the physical and digital worlds 2 Mapping physical systems to a digital representation 3 Sensing the real world 4 Data integration and management 5 Modeling reality 6 Visualization and insight 7 Spatial context and 3D insight 8 Simulation and analysis 9 AI and machine learning integration 10 Digital twins in production Appendix A. Building a LoRaWAN network Appendix B. Building a custom IT sensor Appendix C. Home Assistant Appendix D. Capturing a 3D model using photogrammetry © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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1 Bridging the physical and digital worlds   This chapter covers Defining what a digital twin is  Different levels of digital twin maturity  What digital twins are good for  How digital twins are used across industries  Considerations when embarking on building a digital twin  Digital twins are virtual models of physical systems that continuously synchronize with real- world data to monitor current conditions and predict future behavior. NASA pioneered this approach decades ago with simulators for the Apollo program. Yet for years, digital twins remained accessible only to large, well-funded organizations that could afford the scarce, expensive sensors, computing capacity, and advanced analytics required to build them. That’s all changed. Today, digital twins can be built by almost anybody, with an array of low-cost sensors, high-performance, pay-as-you-go computing, and powerful artificial intelligence and machine learning tools widely available. Some think of digital twins as detailed 3D models. while others see them as glorified dashboards or traditional simulation systems. In this book, we define a digital twin as a system that combines elements from all these interpretations, but is not restricted to any single technology. What exactly counts as a digital twin? Let’s start with a clear definition before exploring why they’ve become so popular. 1 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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1.1 What is a digital twin? In his 1991 book Mirror Worlds, computer scientist David Gelertner imagines building a physical model of a city on your living room floor containing miniature models of buildings and cars, combined with blackboards radiating information related to other things people care about, like the city budget, the air quality, and the waiting time in the emergency room. An army of people would gather data in the city and pass it back to your living room to update this model, allowing you to see, at a glance from your sofa, what is going on throughout the city and use this to influence your own decisions. He then imagines this model living in software, allowing countless people to observe the city simultaneously, each at their preferred level of detail. Around the same time, Michael Grieves was developing similar concepts in the manufacturing world. In 2002, while teaching at the University of Michigan, Grieves presented what he called the "Mirrored Spaces Model" and later the "Information Mirroring Model"—a framework for creating virtual representations of physical products throughout their lifecycle. His work laid the groundwork for what would eventually be called digital twins in industrial settings. What Gelertner and Grieves envisioned has become reality with the emergence of digital twins. The term has been used in many contexts since then and can be defined in different ways, but for this book, a digital twin is defined as: A digital representation of a physical system that is updated with real-world data. It helps users understand current conditions, monitor performance, and simulate scenarios to make better decisions based on clearly defined objectives. Digital twins can also act on the physical system, sending instructions to adjust or optimize its behavior. This definition emphasizes that digital twins should not be built merely because the technology is available, but should serve specific business, operational, or research goals. By providing a computer-based model that mirrors something physical in reality, they help users to comprehend both the state of the object or system, and its structure— how components are organized and connected. By remaining synchronized through continuously receiving updates about current conditions, digital twins allow users to track the behavior of the physical system while also predicting the effect of changes without changing the real system. For most of human history, you had to be physically present to understand how something worked. Digital twins have changed that, and today, countless people can simultaneously monitor, analyze, and run simulations on the same physical system from opposite sides of the globe. 2 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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1.2 Technology enabling digital twins Digital twins first gained traction in capital-intensive industries like manufacturing, utilities, and energy. These industries require massive investments, often operate in remote or hazardous environments, and face strict safety and regulatory requirements. Since equipment costs are high, even small improvements in efficiency or reductions in downtime quickly justify technology investments. While these industries have used operational technology (OT) systems like programmable logic controllers (PLC) and supervisory control and data acquisition (SCADA) for monitoring and control since the 1960s, digital twins represent a major leap forward. By integrating IoT sensors, cloud computing, and AI/ML, modern digital twins can process vast amounts of data, run sophisticated predictive models, and provide actionable insights that traditional control systems alone could never deliver. The convergence of these technologies enables three key capabilities: virtual modeling during design to reduce physical prototyping, predictive maintenance to prevent expensive failures, and real-time optimization to maximize operational efficiency. Consider a wind farm where engineers first use the digital twin to virtually test turbine designs under simulated conditions. Once deployed, IoT sensors stream data to the cloud where AI algorithms detect early signs of bearing wear. The digital twin then simulates maintenance scenarios and schedules repairs, while simultaneously adjusting blade pitch across the farm to maximize energy capture based on real-time weather patterns. 1.2.1 Internet of things (IoT) Not too long ago, measuring things such as temperature, vibration, location, or air quality required bulky and expensive equipment. The affordable and compact sensors available today enable users to capture detailed data about virtually any physical environment or system, opening unprecedented possibilities for monitoring and control. Hobbyists can now build sophisticated home automation systems that measure everything from air quality to energy usage, while startups can deploy sensor networks to monitor equipment performance or environmental conditions at a fraction of historical costs. NOTE The DHT22 sensor that I use to measure temperature and humidity in my home costs around $5 today. Three decades ago, comparable digital measurement required industrial sensors and data acquisition systems costing thousands of dollars, accessible only to well-funded organizations. 3 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Large enterprises leverage these same technologies to enable monitoring of manufacturing lines, predictive maintenance of critical equipment, and optimization of resource usage. The sensors already embedded in smartphones demonstrate the power of this technology, with users able to measure motion, orientation, light levels, and even perform 3D spatial mapping, turning everyday devices into powerful data collection tools. Figure 1.1 shows output from an iPhone’s three-axis accelerometer while the phone is carried in a pocket. The distinctive pattern in this data allows us to infer the physical state of the system, namely that the person carrying it is walking. This democratization of sensing technology means that anyone can now gather the rich, continuous data streams necessary to build digital twins that were once only available to organizations with massive budgets and specialized expertise. 4 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.1 A screenshot shows the output from a 3-axis accelerometer in a modern iPhone in the phyphox app ( https://phyphox. org/) showing data indicating the owner is walking with their phone in their pocket. Such sensor data enables a digital twin to mirror and interpret real-world motion and behavior in real time. 5 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Gathering measurements is only half the story; the data must be sent somewhere useful. Advances in wireless communications have matched this sensor revolution. Fifth-generation (5G) cellular networks offer high speeds for high-bandwidth data. In contrast, Low-Power Wide Area Networks (LPWANs) like LoRaWAN can transmit over 10 km (compared to Wi-Fi’s 50–100 meters) using 10–20 times less power than Wi-Fi. This efficiency enables sensors to run for years on a single battery, making them ideal for small, resource-constrained devices deployed globally. IoT is the combination of these widely available commodity sensors and actuators ("things") embedded into objects and connected to communications networks. As you move through the book, you’ll learn how to wire up a fleet of LoRaWAN-based sensors, route their data through a cloud pipeline, and use it to update a digital twin model in near real time. 1.2.2 Cloud computing In the past, deploying a digital twin was restricted to large industrial players due to the massive upfront investment required for hardware (data storage, analysis, simulation, and 3D rendering). Today, modern public cloud computing provides the essential infrastructure needed to create and operate sophisticated digital twins without that barrier. Users can access scalable compute resources on-demand for complex simulations, elastic storage for continuous sensor data streams, and managed services for data processing, analytics, and machine learning. This pay-as-you-go model eliminates the traditional constraints of purchasing expensive servers and specialized software licenses, allowing rapid prototyping and scaling. Edge computing complements the cloud by processing data closer to where it’s generated. For industrial equipment or remote assets, edge devices perform local analytics, filtering, and decision-making in milliseconds, reducing latency for time-critical operations and minimizing bandwidth costs. For example, a security camera can run a machine learning model to detect defects or safety violations on a production line and transmit only the alerts and metadata rather than streaming hours of raw video footage to the cloud. In this book, we will look at how you can use some of the same cloud services that industrial organizations use today to help you build a digital twin. 1.2.3 Artificial intelligence (AI) and machine learning (ML) The massive datasets from IoT sensors must be filtered, stored, indexed, and analyzed to generate actionable insights. Recent advances in AI and ML, partly enabled by specialized GPU hardware, have shifted these technologies into widespread use. Combined with IoT and cloud computing, they are essential for modern digital twins. AI/ML capabilities are crucial for analyzing continuous sensor streams and making predictions about future system behavior. Cloud providers offer user-friendly tools that make these advanced capabilities accessible. Automated platforms handle the complex process of building, training, and deploying models— pre-processing sensor data, selecting algorithms, and optimizing performance without requiring deep technical knowledge. 6 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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For specific industries, specialized platforms offer pre-built solutions. When real-time responses are critical or cloud connectivity is unreliable, edge computing services allow AI processing to happen locally, enabling immediate decision-making. These tools collectively lower the barrier for organizations to add intelligent prediction, anomaly detection, and automated decision-making capabilities to their digital twins. Furthermore, these capabilities are not only in the cloud. We will look at how you can download pre-trained models for common tasks such as object-detection, and timeseries forecasting, that can be customized and run locally, giving you both control over your data and the ability to operate when internet connectivity is unavailable. 1.2.4 Agentic AI and autonomous decision-making Agentic AI represents a shift toward systems composed of software agents that autonomously reason, plan, and execute complex workflows across digital twins. These agents can monitor systems, learn from data, make decisions, and perform actions to achieve goals like reducing costs or optimizing operations, either individually or in collaboration with other agents. Digital twins feed agentic AI the data it needs, while the AI enhances the twin through autonomous optimization and decision-making. 1.3 What makes a good digital twin? When you hear "digital twin", you might picture a sleek 3D visualization of a complex machine. While visualizations are a common component, they are not the whole story. In fact, some digital twins operate as headless twins—systems focused purely on data processing, analytics, and automated decision-making without any visual component at all. Digital twins range from simple monitoring dashboards to complex predictive and autonomous models. It is useful to categorize them by maturity to help identify the right goal for your needs and measure the expected business value. This book follows the five- level maturity model developed by Verdantix in a 2019 report titled "Smart Innovators: Digital Twins For Industrial Facilities", which categorizes digital twins from basic descriptive systems to advanced autonomous operations, as shown in figure 1.2. 7 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.2 The five categories of digital twin. 1.3.1 Descriptive digital twin At the most basic level is the descriptive digital twin. This twin provides a reasonably static digital representation of a physical object or system, without making real-time predictions or responding to changes. This representation might be a simple engineering diagram or a fully rendered 3D visualization. REAL WORLD EXAMPLE: ONLINE MAPS A familiar example of a descriptive digital twin is Google Maps. What you see when you use this product is a digital model of real-world cities containing roads, buildings, and parks and generated from cartographic maps, satellite imagery and other sources, as shown in figure 1.3. 8 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.3 Google Maps view of lower Manhattan, a familiar example of a descriptive digital twin. Map data © 2025 Google. Google Maps is a trademark of Google LLC. In recent years, Google Maps has evolved from simple two-dimensional maps to rich, photorealistic 3D renderings of the built environment, as shown in figure 1.4. These visuals include buildings modeled through photogrammetry, allowing users to "fly through" cities from the other side of the world, almost as if they were there in person. As one of the largest efforts ever undertaken to capture and represent the physical environment digitally, it is not only a descriptive digital twin itself, but also provides an unprecedented digital foundation for others to build spatially accurate digital twins on top of. 9 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.4 Google Maps view of lower Manhattan showing a photorealistic 3D view of the built environment provides a more detailed example of a descriptive digital twin. Imagery © 2025 Google, Map data © 2025, Map data © 2025 Google. However, the visual representation is only part of the story. Behind the scenes, Google Maps relies on a graph-based model of the road network. Roads are represented as edges in a graph, and intersections are nodes, as shown in figure 1.5. This data structure is what enables turn-by-turn navigation, route optimization, and even traffic prediction. In other words, the visual part of Google Maps is just the surface and underneath is a rich digital model of the physical infrastructure. 10 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.5 A directed graph model of a small subset of lower Manhattan as represented in Google Maps, with vertices representing intersections and edges representing roads with direction of travel. In the context of digital twins, especially descriptive twins, graph-based models allow us to go beyond what we see and start structuring the world in a way that supports higher-level capabilities like simulation, prediction, and real-time analytics. As you move deeper into digital twin maturity, this structural backbone becomes increasingly important. 1.3.2 Informative digital twin An informative digital twin integrates real-time data streams from the physical system to update the digital representation. This allows users to visualize the current state of the system and make better decisions. In Google Maps, adding traffic data creates an informative digital twin at a global scale. This traffic data, gathered from fixed sensors and mobile devices, is rendered by color- coding streets according to traffic density and speed as shown in figure 1.6. This pattern of overlaying data layers on map views is one of the most successful design patterns in informative digital twin development. 11 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.6 Google Maps view of lower Manhattan with realtime traffic congestion data overlaid is an example of an informative digital twin. Imagery © 2025 Google, Map data © 2025, Map data © 2025 Google. REAL WORLD EXAMPLE: TEMPERATURE MONITORING Other informative digital twins offer laid-out dashboards with graphs, gauges, dials, and other components. Figure 1.7 shows one displaying temperature fluctuations over several days inside and outside a building and how the indoor temperature is correlated to that outdoors. Behind this simple visualization lies a network of IoT sensors streaming data into the cloud that is then contextualized (for example, linking an individual sensor to a specific room). It is the combination of data acquisition, processing, storage, contextualization, and visualization that makes informative digital twins so valuable. 12 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Figure 1.7 Information about the physical environment represented in a dashboard forms the basis of many informative digital twins. 1.3.3 Predictive digital twin A predictive digital twin forecasts what the state of the physical system might be in the future and does not only reflect its current state. It uses historical data to anticipate future states of a physical system, based on the assumption that future states and behavior will be consistent with historical patterns. These predictions can range from simple rules, like alerting when a temperature reading crosses a dangerous threshold, to complex machine learning models trained on months or years of operational data. Predictive digital twins are particularly valuable in industries that require extensive and costly maintenance of equipment, as they can help them move from periodic (replace parts every 6 months) or reactive (replace parts when the machine breaks) maintenance to predictive maintenance— replacing parts when they start to exhibit characteristics that may indicate failure. NOTE Predictive digital twins can transform scheduled or reactive maintenance into proactive optimization, fundamentally changing how organizations manage their physical assets and unlock new value-added services. Companies can now offer predictive maintenance subscriptions, performance guarantees, or outcome-based contracts, turning operational insights into revenue streams. 13 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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REAL WORLD EXAMPLE: PREDICTING EQUIPMENT FAILURE Imagine an industrial pump equipped with a temperature sensor. Over time, it starts showing rising temperatures. A predictive digital twin monitoring this pump might be using a threshold-based rule (for example, "if the temperature exceeds 60 degrees Celsius, then trigger a warning") or a more advanced anomaly detection model trained on patterns from pumps that previously failed. The trained machine learning model knows that when the temperature of the pump has exceeded 60 degrees for more than two hours previously, this has caused a failure in the bearing. The goal is to forecast problems before they happen, avoiding costly breakdowns and unplanned downtime. REAL WORLD EXAMPLE: PREDICTING TRAVEL TIME One of the most widely used predictive digital twins is likely in your pocket right now. Open Google Maps, and it will estimate how long it’ll take to drive anywhere you choose, not just based on current traffic, but on what traffic is likely to look like 30 minutes from now, as shown in figure 1.8. How does it do that? Figure 1.8 An example of a predictive digital twin provided by Google Maps showing predicted travel time. Map data © 2025 Google. 14 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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Under the hood, Google uses a Graph Neural Network (GNN) that operates on the road network, treated as a graph, as illustrated in figure 1.6. It blends live traffic data with historical trends to simulate how congestion might evolve. Google Maps combines a static representation of the physical road infrastructure with real time positional data and models trained on historical data to achieve remarkably accurate travel time predictions. The accuracy of these models became apparent during the Covid 19 pandemic when lockdowns shifted traffic patterns overnight, necessitating Google to urgently retrain them on shorter historical traffic data to retain their accuracy. NOTE Read more about how Google DeepMind partners with Google Maps to predict traffic patterns with Graph Neural Networks here https://deepmind. google/blog/ traffic-prediction- with-advanced- graph-neural- networks/. REAL WORLD EXAMPLE: A DIGITAL TWIN OF YOU It is not just machinery and infrastructure that can be modeled in the digital world, but ourselves too. Every time you browse a streaming service or shop online, you’re providing data about yourself to systems that are essentially personal predictive digital twins. These systems build and continuously update a profile of your preferences, beliefs, habits, and behaviors. Based on this profile, they predict which item to recommend on Amazon, what music to queue on Spotify, what search results to return to you in Google, or what you might want to watch next on Netflix as shown in figure 1.9. Figure 1.9 What Netflix thinks I would like to watch next based on its representation of my preferences learned through past shows I have watched. 15 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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The proliferation of these human-centric twins makes robust privacy protocols and clear ethical guidelines essential to prevent misuse, manipulation, or bias in how our digital reflections are managed and acted upon. NOTE Companies such as Delve.ai (https://delve. ai) market software that offers to build a so-called digital twin of a customer (DToC) and a digital twin of an employee (DToE)—with the promise of building a digital replica of a person to make predictions about their performance, behavior, and potential. These predictive digital twins are constantly learning— from your clicks, views, likes, purchases, and even how you move your mouse over the screen. They’re not based on models of physics and are more focused on patterns in data, but the principles are the same: observe the past, understand the present, and forecast the future. 1.3.4 Comprehensive digital twin A comprehensive digital twin takes things a step further. It actively simulates different possible futures in addition to monitoring a system and making forecasts. This lets us explore questions like, "What happens if we tweak this parameter?", "What if we push the system beyond its normal limits?" The goal is to understand how a physical system might behave under various conditions, even if we never touch the real thing. MODELING MEETS REALITY Simulation and modeling of complex systems isn’t new. Engineers and scientists have been doing this for decades, using mathematical models to represent everything from electrical grids to climate systems. Comprehensive digital twins extend traditional modeling by dynamically integrating real-world data, often through techniques such as state estimation or data assimilation. Data assimilation is the process of combining real-world observations with mathematical models to create the most accurate possible representation of a system’s current state. NOTE Data assimilation is like giving your model a regular dose of reality. It compares what the model thinks should happen with what actually happened, then adjusts accordingly. This makes the model not just a static representation of the system that predicts outcomes based on sensor data, but a living, evolving digital counterpart. 16 © Manning Publications Co. To comment go to liveBook Licensed to Ibrahim Mohammed Mohammed <ibrahim@dotnetebusiness.com>
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