R&D Lab »Digital Twins«

Digital twins combine real-world data and simulation models to create digital representations that exhibit the same behavior as their real-world counterparts. They are currently prominent in the field of production engineering. However, they will also play an important role in domains such as automotive and medical engineering.

The research and development work in the »Digital Twins« R&D Lab focuses on simulation and software methods for digitizing products. Using the Karat racing car as an application example, we demonstrate current development challenges of various component parts of an electric racing car. We cover the entire range of the creation of digital twins - from the automated 3D geometry generation of the environment including dynamic semantic understanding, to the creation and validation of physical models of complex components including detailed material descriptions, to the virtual validation of networked, highly automated and complex systems.

The aim of the research work is to dovetail the various digital description levels via suitable interfaces or by co-simulation of cognitive digital twins, using the example of end-to-end multiscale production and product simulation of fiber-reinforced plastic components.

Production plant for sheet molding compound
Production plant for so-called sheet molding compound (or SMC material), a type of fiber-reinforced plastic used in racing cars, for example. For the optimal design of such high-performance parts, the team of the R&D Lab "Digital Twins" carries out simulations for material and structural analysis and also of the manufacturing process.

Our Research on Digital Twins at a Glance:

  • Geometry and semantics
    • Scan-to-twin: creation of dynamic semantic digital twins
    • Visualization of digital twins in AR/VR/XR
  • Material and process
    • Digital twin for fiber-reinforced plastic (FRP) components.
    • Image analysis and simulation of fiber orientation and concentration
    • Evaluation of crash and fatigue behavior of FRP components
  • Systems and infrastructures
    • Methods and virtual test environments for continuous system validation
    • Distributed co-simulation of digital twins with feature interactions
    • XiL-based integration/quality assurance and virtual hardware prototypes


Among others we cooperate with

  • Daimler Truck AG
  • Math2Market GmbH
  • INTELLIGHT® - Intelligent Lightweight Solutions
  • John Deere
  • KARAT e.V. - Kaiserslautern Racing Team
  • Robert Bosch GmbH
Kaiserslautern Racing Team
© Kaiserslautern Racing Team
In the development of the electric race car of the Kaiserslautern Racing Team, various components are simulated as digital twins. Here, the new Electronyte e18 is presented on the race track in Assen.