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Industrial Internet of Things Trends (IIoT)

Simulation advances the IIoT and digital twins by speeding the development of connected hardware and embedded software that create the data used to simulate digital twins of physical assets.

The Industrial Internet of Things (IIoT)

The Industrial Internet of Things (IIoT) creates enormous opportunities for business growth. It connects devices across a wide spectrum of industrial equipment and assets in industries like manufacturing, metal and mining, energy production, processing, transportation and end use applications. These connected devices share data that streamlines business processes and alerts companies to problems in real time, or ahead of time for predictive maintenance.

But the data created by the IIoT is only one piece of the puzzle. Without simulation, much of the data made available by IIoT connection would go to waste. With simulation, it’s possible to create the systems that power the IIoT, and then use the IIoT data to create digital twins of physical assets that let us better understand systems, predict problems and failures, optimize processes and improve production time and costs.

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    Minimize Downtime
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    Capture and Analyze Real-World Data
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    Test Repairs Before Implementation
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    Make Confident Predictions About Product Performance

Unlock your Business's Full Potential with the IIoT

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Create and Monitor Digital Twins

Data from connected sensors and actuators on a deployed product are used to create a digital twin that can be analyzed for optimization.

Reduce Costs

Virtual solutions testing and an accurate understanding of the real-time status of a deployed product can reduce unnecessary downtime and wasted materials.

Predictive Maintenance

Data from digital twins augments regular maintenance schedules and enables accurate prediction of problems before they arise.

Connect the Edge to the Enterprise

Smart devices in the field allow monitoring of your whole system based on current data, not historical averages.


The Internet of Things represents a staggeringly complex ensemble of interconnected products, devices and systems. Each component and subcomponent in the system affects and is affected by all the others. To ensure cost-effective and timely development, successful engineering of IIoT products relies on numerous applications, including antenna design and placement, chip-package system development, power electronics, electromagnetic interference/compatibility (EMI/EMC), electronics reliability and battery simulation.

Digital Twins: Making the Vision Achievable


Digital twins have the potential to revolutionize how manufacturers do business in industries like oil and gas, automotive, and aerospace and defense

Since the idea of a digital twin first took hold, the potential benefits have been obvious. Digital twins mean minimized or eliminated downtime, thanks to predictive maintenance, reduced labor costs and new insights for developing next-generation technology based on huge amounts of complex, real-world data. Unfortunately, implementation has historically been almost prohibitively difficult. Modern simulation solutions have finally cracked the implementation barrier and made the digital twin vision a reality.

Because of the huge array of benefits — both in terms of immediate cost-savings and informed decision making for the future — the industry leaders of tomorrow will be those who implement these game-changing technologies today. Digital twin technology is an investment that will keep adopters at the forefront of their industry for years to come.

Double Down on the IIoT With Digital Twins

Digital twins represent a huge cost savings for companies that implement them, but the benefits don’t stop there. They can also help you unlock new revenue streams and reignite your business.


Predictive maintenance greatly reduces the volume of warranty claims made by customers.

Manufacturers can use predictive maintenance to optimize operations and reduce warranty and insurance claims. Some manufacturers see savings as high as 3% of product revenues.


Deploying a digital twin to an IIoT platform reduces maintenance costs.

Once installed in the field, an IIoT-connected device paired to a digital twin can reduce lifetime maintenance costs by 20%.


Digital twins create new revenue streams in the form of high-value service offerings.

Studies indicate that manufacturers show an average of 25% margin for aftermarket services, compared to only 10% margin for new equipment.

Ansys Expertise

Featured Events

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Building Digital Twins with an End-to-End Workflow

Join us for this webinar and discover how Ansys Twin Builder’s unique workflow helps you build, validate and deploy simulation-based digital twins with a real-world industrial application.

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3D Field Meta Models for Digital Twins with Ansys optiSLang

This webinar gives an overview of the capabilities of Ansys optiSLang in reduced-order modeling. 

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Reduced Order Models (ROMs) for Simulation Democratization and Digital Twins

In this webinar, a series of ROMs will be shown, along with the workflow to create the ROMs. These examples will highlight how ROMs can be used by operators/non-simulation experts to perform ‘what-if’ analysis within seconds without compromising on accuracy.

Featured Resources

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Connecting Simulation to the Digital Thread

In this webinar, we’ll explore how Ansys Minerva, built on the Aras platform, alleviates many challenges, such as collaboration, visibility, traceability and business challenges like governance, productivity, reuse and enterprise wide deployment of best practices.


Seven Crucial Applications to Successfully Engineer the Internet of Things

The internet of things and the products and devices that make it work are incredibly complex, consisting of everything from mammoth data centers to tiny solder balls on a chip. Each component and subcomponent is affected by the other components and the environment in which each operates. Seven applications, enabled by simulation, are critical to cost-effective and timely development of IIoT products. 


SkyCell Saves Lives With the IIoT

SkyCell designs, creates and manages smart, durable air freight containers for transporting vaccines across the globe. The containers are constructed with a bespoke material, require no direct human management, control their own temperature and report their location in real-time. SkyCell uses Ansys HFSS, Ansys CFD and Ansys Mechanical to simulate a holistic view of Internet of Things (IoT) components, air and energy flows, and the structural integrity of the container.



White Paper

Edge Computing: New Support for Digital Twins

Digital twins are one of the most exciting technology developments to emerge over the past few years. By creating a virtual model of a physical product, then simulating its real-time operation, companies are optimizing maintenance, predicting critical maintenance events and fueling innovation via actual performance feedback.



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Ansys and Microsoft Work to Improve Digital Twin User Experiences

Engineers are tasked with the continuous improvement of the products, services and systems they design. The trouble is, once a product is out in the field, it’s hard to know how that design is performing — or being used. By coupling digital twin and internet of things (IoT) technology, engineers can get a better idea of a product’s real-world performance...

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How to Create a Digital Twin

When Joseph Strauss, Leon Moisseiff and Charles Alton Ellis designed San Francisco’s Golden Gate Bridge in 1917, the engineers likely knew it would become a world-famous bridge. After all, when it opened in 1937, it was the longest and tallest suspension bridge in the world. They would have had no way of imagining that other engineers would one day create a digital twin of the bridge, but that’s what engineers at Ozen Engineering have done with the help of Ansys software...

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