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Ansys Twin Builder

Create and Deploy Digital Twin Models

Ansys Twin Builder is an open solution that allows engineers to create simulation-based digital twins–digital representations of assets with real-world or virtual sensor inputs.

Build, Validate and Deploy Simulation-Based Digital Twins with Ansys

Build, Validate and Deploy Simulation-Based Digital Twins

An analytics-driven, simulation-based digital twin is a connected, virtual replica of an in-service physical asset — in the form of an integrated multidomain system simulation —that mirrors the life and experience of the asset. Hybrid digital twins enable system design and optimization and predictive maintenance, and they optimize industrial asset management. By implementing Ansys Twin Builder, you can improve top-line revenue, manage bottom-line costs and both gain and retain a competitive advantage.

Quick Specs

Ansys Twin Builder enables you to quickly create a digital twin–a connected replica of an in-service asset. This allows for enhanced lifecycle management and true predictive maintenance, saving costs to help maintain a competitive advantage.

  • Build Your Twin
  • Digital Twin Runtime Capabilities
  • Validate Your Twin
  • Hybrid Analytics
  • Deploy Your Twin


What's New

Ansys Twin Builder 2022 R1 delivers predictive analytics with an unparalleled level of accuracy by combining physical and virtual sensors. New features enable faster deployment of your digital twin, easier workflows, and web application for online interaction with your model.

Hybrid Digital Twin
Accelerate Export and Deployment of Digital Twin
  • Increase digital twin accuracy up to 98% with new Hybrid Digital Twin technology 
  • Quickly develop web-apps that interact with your Twin
  • Control your Twin easily via APIs, without loss of data
Constraints on Rom
Maximize the control of your Reduced-Order Model (ROM)
  • Control ROM output to ensure ROM outputs meet physical constraints
  • 10x faster ROM simulations with New Dynamic ROM Builder engine
Digital Twin Modelica Conditional Connector
Better Workflow & User Experience
  • Customize components with the help of conditional connectors and parameters
  • Several customer-driven User Experience enhancements make creating models and twins easier

Fail-Safe Digital Twin

Using digital twins to predict failures in advance.

ansys digital twin case study

Phoenix Contact Electronics engineers used ANSYS software to develop a digital twin of its safety relays that will integrate real-time sensor data with simulation results to predict failures in advance.

Configurable safety relays are implemented in factory automation to help prevent injuries and equipment damage by cutting off electrical power in response to sensor data. When a relay fails, production must be halted for repairs, meaning downtime often costing many thousands of dollars. The normal alternative is to change relays on a schedule that occurs well before actual failure.

Using ANSYS Twin Builder, engineers at industrial electronics manufacturer Phoenix Contact Electronics have developed reduced-order models to help determine a relay’s usable lifetime. This advanced modeling takes into account difficult-to-observe factors that affect longevity, such as a relay’s armature rotation angle and contact bounce time. The system has been validated on a demonstrator relay, and this solution is now being integrated into relays used in real-world applications. 


View all Applications
Battery management systems for electric vehicles

Battery Management Systems

Ansys offers an integrated solution for battery management system (BMS) design and development that allows for risk-free virtual testing.

Electrified powertrain system integration

Vehicle Powertrain Simulation Software

Integrate highly complex, electric vehicle and hybrid-electric vehicle powertrains and their subsystems and components with Ansys simulation software.

Industrial Flow Networks

Industrial Flow Networks

Leverage Ansys Digital Twin for your industrial flow network. Integrate model-based design, simulation, and actual asset performance.

Digital twins lab simulation

Case Studies

infographic Twin Builder

Unlocking the Value of Digital Twins with Ansys Twin Builder

This infographic details the amount of time and money you can save, along with new revenue streams you can generate, using Ansys Twin Builder.

digital twins white paper

Digital Twins: Making the Vision Achievable

Learn about Ansys' best-in-class solution for creating, validating, and deploying digital twins in this white paper.

Battery Systems ansys

Managing Large-Scale Battery Systems

Battery management systems (BMS) are essential components that leverage embedded software for real-time monitoring and control of rechargeable batteries in complex applications.

ansys battery pack

Digital Twin Prevents Drain on Battery Pack Simulation Time

See how working with Ansys tools such as Twin Builder can reduce the amount of time battery pack and thermal management simulation takes.

Ansys Twin Builder creates connected, virtual replicas of an in-service physical asset

Ansys Twin Builder is a uniquely open solution that allows engineers to create digital twins–connected, virtual replicas of in-service physical assets. Digital twins enable true predictive maintenance, allowing for cost savings, and the proactive optimization of an asset’s operation. Ansys Twin Builder lets you build, validate and deploy the twin, potentially cutting the time required to create an accurate product model in half. Once deployed, users can expect a 25% increase in product performance, and maintenance cost savings of up to 20% over the product’s lifetime.


Key Features

Ansys Twin Builder features a wide range of capabilities for modeling and simulation of in-service assets.

  • Multidomain Systems Modeler
  • Extensive 0D Application-Specific Libraries
  • Third-party Tool Integration
  • Reduced Order Models (ROMs)
  • Embedded Software Integration
  • Multidomain Systems Solver with Integrated Post-Processing
  • Rapid HMI Prototyping
  • System Optimization Tools
  • XIL Integration
  • IIoT Connectivity and Twin Verification and Validation (V&V)
  • Twin Deployer

Create hierarchical schematics of complex power electronic circuits and multidomain systems. Model with standard languages and exchange formats.

Twin Builder models are easily parameterized to replicate physical component behavior. They include analog and power electronics components; control blocks and sensors; mechanical components; hydraulic components; digital and logic blocks; application-specific libraries for aerospace electrical networks, electric vehicles and power systems; and characterized manufacturers' components. Twin Builder supports the Modelica Standard Library and Modelica libraries offered by Modelon AB, including libraries for hydraulics, pneumatics, liquid cooling, heat exchangers and thermal power.

With over 100 tools now officially supporting FMI model export and cosimulation, including GT-SUITE, CarSim, Amesim and Dymola, full-system models can be assembled in Twin Builder to take advantage of its high-performing solvers and links with Ansys 3D physics. Additional interfaces allow the direct integration of C/C++ code and MathWorks Simulink models. Twin Builder models can also be exported for use in FMI-compliant environments.

Twin Builder uses ROMs produced from Ansys structural, fluids, electromagnetics and semiconductor products to model mechanical assemblies; electromagnetic actuators and machines; circuit and cable parasitics; thermal networks; and signal integrity. 3D ROMs can be created in Workbench and imported into Twin Builder. ROMs can also be imported from a variety of third-party tools, such as optiSLang. Co-simulation with 3D physics solvers preserves the full accuracy of FEA and CFD for modeling fluid components and flow networks, rigid and flexible-body mechanical assemblies, and electric machines and actuators. Get an easier access to all ROMs in one easy place with the ROM ribbon and gallery.

Tight coupling with Ansys SCADE Suite and SCADE Display permits interactive monitoring and debugging during software execution. Custom code and third- party controls can be incorporated into a Twin Builder system model through standard interfaces (e.g., FMI) or a robust API.

With adaptive time-step controls and sophisticated solver synchronization capabilities, Twin Builder performs efficient and accurate simulation of continuous-time, discrete-time and analog/mixed-signal behaviors. Twin Builder simulations can be executed on high-performance compute resources, and multi-run analyses can be executed in parallel to increase simulation throughout.

This enables you to create interactive panels using predefined widgets (buttons, sliders, etc.) to interact with the application under test. It empowers model simulation. Early requirements validation is made possible through a variety of features.

Twin Builder provides a full environment for testing system behavior, allowing basic simulation experiments to be performed in the steady-state, time and frequency domains.

Twin Builder provides links with popular embedded control design tools, including the Ansys SCADE tool suite and MathWorks Simulink.

Twin Builder's built-in APIs provide seamless connection to Microsoft® Azure® IoT, Microsoft Azure Digital Twins , PTC ThingWorx®, SAP Predictive Asset Insights, Rockwell Automation Emulate 3D and  Rockwell Studio 5000. Twin Builder can also connect to all other IIoT platforms, including homegrown varieties, allowing you to perform predictive maintenance on your physical asset. You can also easily deploy digital twins with Ansys Twin Deployer. Twin Deployer helps you significantly reduce deployment time by performing V&V on twins, and easily deploying the twin using cloud, edge or offline computing resources. Twin Builder also supports generating images from deployed twins.


Featured Events & Webinars

Webinar Series
Digital Twins Webinar Series
Digital Twins Webinar Series

Build, Validate and Deploy Simulation-Based Digital Twins

During these 60-minute sessions, our experts will demonstrate the power of Ansys Twin Builder to Build, Validate and Deploy Simulation-Based Digital Twins in various Industries and Applications.

On Demand Webinar
Ansys Fluid Power
Harnessing the Power of The Twin Builder Fluid Power Library to Quickly Build Systems Models and Digital Twins

Learn about the ANSYS Twin Builder Fluid Power Library for industrial applications from drills and gearboxes to automotive suspension systems and aircraft landing gear.

On Demand Webinar
Ansys Building Digital Twins
Building Digital Twins with an End-to-End Workflow

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

Case Studies

Ansys Case Studies twin-builder

Unlocking the Value of Digital Twins with Ansys Twin Builder - Infographic

This infographic details the amount of time and money you can save, along with new revenue streams you can generate, using Ansys Twin Builder.

Ansys Case Study iot

Ansys Wins Prestigious Industrial Internet of Things Award

Fourth annual Internet of Things Breakthrough Awards recognizes Ansys’ digital twin simulation solution.

Ansys Case Study pump

Creating a Digital Twin for a Pump

Technologies now make it possible to integrate simulation with products as they exist and operate in the real world. This enables companies to optimize operations and maintenance, as well as further accelerate the new-product development process.

Ansys Case Study Battery Pack

Digital Twin Prevents Drain on Battery Pack Simulation Time

See how working with Ansys tools such as Twin Builder can reduce the amount of time battery pack and thermal management simulation takes.

Ansys case study digital twin

How to Create a Digital Twin

Learn how Ozen Engineering used Ansys Twin Builder to create a digital twin of the Golden Gate Bridge.


Ansys software is accessible

It's vital to Ansys that all users, including those with disabilities, can access our products. As such, we endeavor to follow accessibility requirements based on the US Access Board (Section 508), Web Content Accessibility Guidelines (WCAG), and the current format of the Voluntary Product Accessibility Template (VPAT).

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