Your HMI is Still 2D? Here’s What You’re Missing

Thomas Strigl, 11.09.2025
realvirtual.io | Flexible, modular 3D simulation & virtual commissioning with Unity – real-time, customizable, automation-ready

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Last week, I watched an experienced operator spend 15 minutes clicking through seven different HMI screens trying to locate a sensor fault. The sensor? It was physically 2 meters from where he stood. The problem wasn’t the operator—it was that our traditional HMIs force us to think in abstract symbols and panel hierarchies when the real world is three-dimensional.

Meanwhile, the same operators navigate complex 3D worlds on their phones during break time playing games. Why are we still using 1990s-style interfaces for million-euro automation systems?

The Expensive Reality of 2D Thinking

Every day, operators see cryptic messages like “BG1_CNV3_S47 FAULT” and waste precious minutes decoding what it means, where it is, and how to fix it. On production lines worth thousands per hour, those minutes add up fast.

The real problem isn’t the complexity of our machines—it’s how we visualize them. Consider this: A single production line can cost €5-20 million. Downtime costs €5,000-50,000 per hour. Lost customers from delayed deliveries? Priceless. Yet we still interact with these critical assets through interfaces that haven’t fundamentally changed since the 1990s.

Unity: Not Just Another Simulation Tool

Here’s what makes Unity fundamentally different from traditional “simulation” systems: It’s a complete platform that spans your entire machine lifecycle.

Traditional simulation tools are typically locked into one phase. You have sales tools that can’t connect to real PLCs, engineering simulations that can’t become operator interfaces, and virtual commissioning systems that disappear after startup. Each phase means new software, new models, new training, new costs.

Unity breaks these silos completely. The same 3D model flows seamlessly from sales presentations that win contracts, through engineering simulation that validates designs, into virtual commissioning that tests control logic, then operator training before the machine arrives, and finally becomes the 3D HMI delivered with the machine. One model, one platform, from concept to customer.

This isn’t theoretical. Mercedes-Benz is using Unity for their MB.OS infotainment system, citing faster development cycles and superior real-time 3D visualization. But your production line is far more complex than any car—and the ability to maintain one consistent digital twin throughout its lifecycle is a game-changer traditional simulation vendors simply can’t match.

What 3D HMI Actually Means

Forget fancy animations. I’m talking about practical interfaces that show your actual machine in real-time 3D, with live data exactly where it belongs—on the machine itself.

When a sensor triggers, operators see it highlighted on the actual component in a 3D view they can rotate and zoom. Click it to access live values and history, maintenance documentation, spare part information, and related PLC variables. No translation needed. No hunting through screens. The machine looks like the machine.

From Cryptic Errors to Instant Solutions

Here’s what we demonstrate in our ModelZoo example. A stacker crane throws error “42.1 (2A01hex | 10753dec)”. In a traditional HMI, good luck figuring that out without the manual.

With 3D HMI and AI integration, the operator clicks the highlighted drive on the 3D model and instantly sees a clear explanation: “Positioning Slip Error – Motion deviated beyond allowable threshold during positioning.”

But it doesn’t stop there. The system presents common causes like encoder wiring faults, misalignment, or mechanical binding, followed by specific recommended actions. First, verify encoder cable integrity and secure connectors. Then confirm correct encoder mounting and axis alignment. Finally, check motor phase-to-feedback mapping in drive parameters.

No more panic calls. No production stops. The solution is right there, in context, when it’s needed.

Build Once, Deploy Everywhere

The real power of Unity becomes clear when you realize you can deliver a standalone 3D application with your machine. No special software licenses for your customer. No cloud dependencies. No complex IT requirements.

Export your Unity-based 3D HMI as a Windows executable that runs on any industrial PC, a WebGL application accessible from any browser, an Android or iOS app for tablets on the shop floor, or even embedded Linux for panel PCs. Your customer gets a professional 3D interface that’s part of the machine—not an expensive add-on they need to license separately.

This is unique in the industry. Traditional simulation vendors lock you into their ecosystem with runtime licenses, cloud subscriptions, and vendor dependencies. With Unity, you own your solution completely and can deliver it however makes sense for your customers.

Getting Started Without the Drama

Want to experiment before showing anyone? Smart approach. Download realvirtual.io Starter free from the Unity Asset Store. Open the demo scene—it’s a complete digital twin with drives, sensors, and PLC interface already configured. Play around with it. Trigger sensors, move axes, simulate faults. When you’re ready, test it with the included Siemens S7 simulation, then import your own CAD to see how it works with your actual machines.

Ready for production? realvirtual.io Professional connects to virtually any industrial system. From Siemens S7 and TwinCAT ADS to Allen-Bradley, Modbus, and OPC UA for PLCs. MQTT, REST API, and Azure IoT for cloud connectivity. WebSocket interfaces for browser-based deployment. Everything you need is already there, tested and proven in production environments.

ModelZoo: Show Your Management the Vision

Download our ModelZoo stacker crane example—a complete 3D HMI with AI-powered error diagnosis. But don’t just show them the interface. Show them the entire lifecycle value. The same model that impresses customers in sales presentations becomes the actual operator interface. No vendor lock-in or recurring licenses. Delivered as part of your machine, adding value without adding complexity.

When management sees operators solving problems in 2 minutes instead of 15, when they understand you can deliver this capability with every machine without licensing headaches, when they realize competitors are still shipping 2D panels—that’s when the decision becomes obvious.

The Bottom Line

Your machines are too valuable, too complex, and too critical to operate through 2D abstractions. But more importantly, they’re too valuable to be limited by traditional simulation tools that only work in one phase of the lifecycle.

Unity with realvirtual.io gives you something unique: A platform where your digital twin grows with your machine, from the first customer presentation to daily operations. Build it once, use it everywhere, deliver it with pride.

The companies implementing this approach today aren’t just reducing downtime—they’re differentiating their entire offering. In a world where every machine builder claims “Industry 4.0,” they’re actually delivering it.

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P.S. – Start with realvirtual.io Starter free today. Build a prototype. Show your team. When they ask “Can we deliver this with our machines?” the answer is yes—without licensing headaches or vendor dependencies. That’s the Unity difference.

Get realvirtual.io Starter | Download ModelZoo | Explore Professional

Accelerating AI Training with Digital Twin Technology: How realvirtual.io AI Builder is Changing the Game

Thomas Strigl, 25.10.2024
realvirtual.io | Flexible, modular 3D simulation & virtual commissioning with Unity – real-time, customizable, automation-ready

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In the world of industrial automation and AI development, speed and precision are crucial. Traditional AI training approaches often struggle to keep pace with the rapid advancements in technology. That’s where digital twin technology steps in, providing a revolutionary way to enhance AI training and deployment. With the introduction of the realvirtual.io AI Builder, organizations can now train AI vision systems within a digital twin environment, dramatically reducing development time and improving performance.

Let’s explore how realvirtual.io AI Builder is redefining the landscape of AI training using digital twin technology and Unity’s powerful 3D capabilities.

The Power of AI Training in a Digital Twin

A digital twin is a virtual representation of a physical system that can be used for simulation, analysis, and optimization. When combined with AI training, it enables the development of machine learning models in a safe, controlled, and highly realistic virtual environment.

This approach offers several advantages over traditional methods. Training AI vision models in a digital twin allows for rapid iterations and adjustments. The virtual environment can simulate various scenarios that would be difficult or time-consuming to reproduce in the real world. One of the most significant challenges in AI training is acquiring sufficient quality data. Digital twins can generate high-quality synthetic data for training, filling in gaps where real-world data might be scarce or difficult to collect. This ensures the AI system is exposed to diverse situations, leading to more robust model performance.

Testing AI algorithms in real industrial environments can be risky and costly. A digital twin offers a risk-free way to validate AI performance, allowing for thorough testing without disrupting ongoing operations or endangering equipment and personnel.

How realvirtual.io AI Builder Enhances AI Vision Development

The realvirtual.io AI Builder is designed to make AI vision training and deployment more efficient by leveraging a fully integrated digital twin environment based on Unity’s Real-Time 3D capabilities.

The AI Builder offers an integrated training pipeline, making it easy to move from data preparation to AI model training, testing, and deployment. The platform supports the use of synthetic data generated within the digital twin, enabling faster model training. By using Unity’s 3D engine, the AI Builder provides realistic and dynamic simulations for AI vision training. Developers can create complex and detailed digital twins that mirror real-world systems, allowing the AI to learn in an environment that closely replicates actual conditions.

Once trained, AI models can be exported using the ONNX (Open Neural Network Exchange) format for deployment. The AI Builder supports integrated inference capabilities, ensuring that models can be efficiently deployed and executed across different platforms. The digital twin environment allows developers to continuously refine AI models by running simulations of various operating conditions, quickly identifying areas for improvement, and iterating accordingly.

Use Cases: Where Digital Twins and AI Vision Make a Difference

The combination of digital twins and AI vision can be transformative in several industries. In manufacturing and automation, by simulating factory floor operations, AI models can be trained to identify defects, predict maintenance needs, and optimize production lines. For logistics and robotics, training AI systems to navigate warehouses, sort products, and manage inventory in a digital twin ensures that robots and automated systems operate with greater efficiency and accuracy. In smart cities and infrastructure, digital twins can represent urban environments, allowing AI vision models to be trained for traffic monitoring, public safety, and infrastructure management.

Why Choose realvirtual.io AI Builder for AI Training?

The realvirtual.io AI Builder combines the flexibility and power of Unity’s real-time 3D capabilities with cutting-edge AI training tools. Train AI models at lightning speed, thanks to synthetic data generation and rapid iteration cycles in the digital twin environment. Develop and validate AI systems in a virtual environment before deploying them in the field, reducing risks. The platform supports seamless export and integration of AI models using ONNX, ensuring compatibility with various deployment platforms.

Conclusion

As AI continues to transform industries, the demand for faster, more efficient training and deployment methods will only grow. The realvirtual.io AI Builder is at the forefront of this evolution, offering a platform that brings together digital twins, AI vision development, and Unity’s real-time 3D capabilities. With its ability to accelerate training, enhance data quality, and reduce risks, AI Builder is setting a new standard for AI development.

Explore how you can leverage the power of digital twins for your AI projects with realvirtual.io AI Builder. The future of AI vision is here – and it’s faster, safer, and smarter than ever before.

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Learn More About AI Builder | Download realvirtual.io | Contact Us

Let’s Stop Buzzwording – A Call for Real Conversations

Thomas Strigl, 18.09.2024
realvirtual.io | Flexible, modular 3D simulation & virtual commissioning with Unity – real-time, customizable, automation-ready

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As I walked around Hannover Messe early this year, one thing stood out: everywhere I turned, I saw the same buzzwords plastered prominently — Metaverse, Industry 4.0, Industrial Edge, Digital Twin, AI. These terms are not new, yet they’ve become the default language at almost every booth. Major companies, from large ones to innovative startups, all showcased these concepts as if they were the silver bullets to success.

But maybe it’s time to ask: are we focusing too much on the buzzwords and not enough on the substance? Are these words actually driving innovation, or have they become catch-all phrases that obscure the real work happening behind the scenes?

The Buzzword Bubble

There’s no denying that terms like Industrial Metaverse, Industry 4.0, and Digital Twin encapsulate important technological advancements. They serve as shorthand for complex ideas about the future of industry, automation, productivity, and connectivity. But the more we use them as marketing phrases without a direct relation to the use case, the more they risk losing their meaning. When every company adopts the same lingo, it becomes harder to differentiate between real innovation and empty promises.

At events like Hannover Messe, where some of the most forward-thinking technology is showcased, it was hard for me to ignore how oversaturated I’ve become with this kind of jargon. It’s almost like we’ve created a buzzword race where everyone is trying to outdo each other with the same terms, rather than explain what they’re actually doing.

The Real Terms Matter

What if, instead of leaning on flashy buzzwords, we focused on the actual tools and benefits that lie behind them? Take the Digital Twin, for example. What’s often hidden behind this trendy phrase are critical technologies like material flow simulation for detecting bottlenecks and optimizing output. Virtual commissioning that reduces commissioning times and speeds up ramp-up time for new production systems. 3D visualization that creates immersive, visual representations to sell and better understand system behavior. VR training for complex machines in complicated processes. Production and product data management throughout the lifecycle for faster workflow and quicker decisions. Industrial vision with AI detecting products, positions, and defects using AI-trained cameras in production.

These are examples of real use cases and the real solutions driving innovation today. Yet, they’re often overshadowed by the broader concept of a “Digital Twin.” Instead of showcasing these tangible benefits, we’re too often caught up in presenting the umbrella term without diving into the details.

When Buzzwords Get in the Way

At realvirtual.io, we’ve experienced firsthand how buzzwords can lead to confusion. We were recently asked for a large RFQ from a major company requesting a Digital Twin platform. The problem? The company wasn’t even able to define what they wanted to use the Digital Twin for! Autonomous robot development, material flow simulation, bottleneck detection, 3D visualization of their systems, continuous decision-making, production planning? It’s a classic case of buzzwords taking over, driven by marketing campaigns and consultancy advice.

How can you offer a fixed price for something when the purpose is unclear? This situation highlights a real risk: buzzwords like Digital Twin sometimes influence decision-makers, leading to requests without a clear understanding of use cases or benefits. Decisions end up being made by management swayed by trending terminology, rather than by real value-driven needs.

Even more concerning is how quickly some people and companies adopt buzzwords before the real benefits are fully developed or proven. There’s a rush to embrace the latest trend without taking the time to ensure the technology will actually deliver meaningful outcomes. In this race to stay relevant, the actual value of the technology can be overlooked, and opportunities for real impact are missed.

Big Brands Blocking Markets

In my experience, buzzwords are not only confusing—they can also block markets. When industry giants like Amazon, NVIDIA, Microsoft, or Siemens push their own versions of a Digital Twin, it creates a barrier for smaller, more innovative companies. If these big players are already in the game, why would a company go with a solution from a smaller, emerging firm?

The dominance of these brands can stifle innovation. They put the buzzword out front, and their sheer market presence often makes management hesitant to consider alternatives, regardless of whether the bigger brands’ solutions really provide any benefit. I should know why to put Digital Twin data into the cloud before using it. The result is slower decision-making, missed opportunities for smaller players, and ultimately, a market where management feels pressured to align with “safe” choices rather than the best solutions.

Focus on Benefits, Not Buzzwords

At the end of the day, the goal is not to sell buzzwords, but to highlight the tangible value these technologies offer. We should be asking ourselves: what does this solution actually do for businesses? How does it address specific challenges? Does it cut costs, improve efficiency, or enhance safety?

Shifting the Conversation

So, how do we move beyond buzzwords? Rather than relying on big, shiny terms, we need to focus on showing real-world applications. Walk your audience through how your tech solution changes the game, step by step. Let’s be honest about where the technology is right now. The Industrial Metaverse may be an exciting concept, but we’re still in the early days. Instead of overpromising, explain what’s achievable today, and how it fits into the bigger vision.

Instead of falling back on industry buzzwords, tailor your message to the use cases, needs, and concerns of your audience. What’s their pain point? How does your solution address that? Highlight the genuine breakthroughs happening within your company or industry. Talk about the hard problems you’re solving, the process you went through, and what the next steps are. This is where meaningful conversations start.

Our Commitment at Realvirtual.io

At realvirtual.io, we’re taking this message to heart. Moving forward, we’ll strive to use more value-defining words in our marketing communication. Instead of hiding behind buzzwords, we’ll focus on clearly communicating the real benefits our solutions provide—whether it’s material flow simulation, virtual commissioning, 3D animation, or AI training for industrial vision. Our goal is to highlight how these technologies truly improve operations and solve real challenges.

The Way Forward

As exciting as it is to live in a world of Industrial Metaverses and Digital Twins, we owe it to ourselves—and our industries—to push past the surface and get to the heart of what matters. Let’s stop buzzwording, and instead focus on real, actionable conversations about how we’re changing industries, solving problems, and building the future.

What do you think? Are you ready to move past the buzzwords? Let’s talk about the real benefits of the technologies driving your business forward.

 

The Shifting Landscape of Industrial Simulation: Unity, Unreal Engine, and Omniverse

Thomas Strigl
realvirtual.io | Flexible, modular 3D simulation & virtual commissioning with Unity – real-time, customizable, automation-ready

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The industrial simulation market is indeed undergoing significant changes, driven by the advancements in real-time rendering technologies and the integration of CAD data into game engines like Unity, Unreal Engine, and Omniverse. These engines have disrupted traditional product rendering and is, this is my bet, going to disrupt simulation and industrial engineering tools from companies like Siemens and Dassault, offering faster and more visually appealing solutions.

The Rise of Game Engines in Industry

RealVirtual.io’s push for Unity as a game engine-based solution for industrial use cases aligns with the increasing adoption of Unity in various industries, including engineering, architecture, and training simulations. Unity’s user-friendly interface, extensive asset store, and cross-platform compatibility make it an attractive choice for developers and engineers seeking efficient prototyping and integration capabilities.

On the other hand, Omniverse, backed by NVIDIA, and Unreal Engine, developed by Epic Games, also present formidable competitors in the industrial simulation space. While NVIDIA aggressively markets Omniverse’s industrial use cases, Unreal Engine’s focus on high-fidelity graphics and realistic rendering capabilities makes it equally attractive for industries that require photorealistic simulations.

The CAD Integration Advantage

One notable advantage shared by all three engines is their ability to import CAD data seamlessly, leveraging plugins like PixYZ for Unity, Datasmith for Unreal Engine, and Omniverse’s CAD converter. This allows for quick and convenient integration of complex CAD models, enabling engineers to rapidly prototype and visualize their designs.

In terms of visual quality, both Unreal Engine and Omniverse have been praised for their realistic rendering capabilities, often making it easier to achieve high-fidelity visuals compared to Unity. However, Unity has been closing the gap with the introduction of new rendering pipelines and post-processing features, making the quality across all three engines comparable.

Traditional Players Adapting

With the rising demand for more immersive and realistic visualizations, traditional simulation and engineering software providers, such as Siemens, are recognizing the need to partner with Omniverse to stay competitive in terms of visual quality. This partnership enables them to leverage the advanced rendering capabilities of these engines without having to rebuild the entire simulation infrastructure from scratch.

Similarly, traditional simulation solutions like Visual Components are offering interfaces for Omniverse to cater to the growing interest in NVIDIA’s collaborative platform. This move allows industries to benefit from the strengths of both traditional simulation software and Omniverse’s real-time collaboration and rendering capabilities.

However, you are right in highlighting the concern of potential “lock-in” situations. Partnering with Omniverse can create a situation where industries become dependent on multiple platforms and technologies, leading to increased complexity and potential vendor dependency. This can result in higher costs for two expensive systems and challenges in managing data and workflows across different systems.

Why Unity Makes Sense for Industrial Applications

Why do we remain confident that realvirtual.io based on Unity is the right choice for our market? As of now, I don’t believe integrating with Omniverse is necessary. Personally, I find Omniverse’s development platform somewhat unfamiliar. The visual representation of a machine is stored in a USD file, but you need to additionally load the code to run this Digital Twin on your computer. While the 3D data might be available for multiple users to edit simultaneously, the required code for running the machine simulation operates on each individual workstation. While it might be feasible to stream the data from a server, this approach appears overly complicated for certain use cases.

On a personal note, I prefer the approach taken by Unreal and Unity. In those engines, a model combines 3D data with the connected code. You can save a model as a file, open it, and simply run it. Additionally, distributing the digital twin becomes effortless with Unreal and Unity. Similar to building a game, you can deploy a digital twin built on Unreal and Unity to various platforms, such as Windows or mobile applications. There’s no need for complex server rendering, hardware setup, or installations on the recipient’s side. They can just start the digital twin and use it.

The Power of Platform Independence

The ability to distribute the Digital Twin on different platforms is a crucial advantage that fosters a vendor-independent business model. By using game engines like Unreal and Unity, you gain the flexibility to deploy the Digital Twin as an iOS or Android app, making it easily accessible to customers on their preferred mobile devices. Whether it’s for machine demonstrations or interactive 3D HMIs, creating Windows or WebGL applications allows seamless integration with the machine and simplifies the delivery process to end customers.

This approach liberates businesses from complex cloud setups or dependency on specific vendors like Nvidia or others. Instead, it empowers companies to have full control over the distribution and accessibility of their Digital Twin solutions. Whether it’s for in-house demonstrations, client presentations, or end-user interactions, the ability to deploy the Digital Twin on a variety of platforms ensures wider reach and accessibility, ultimately enhancing the user experience and facilitating customer engagement.

By leveraging the portability of Unreal and Unity-built applications, companies can tailor their Digital Twin offerings to the specific needs and preferences of their clients, regardless of the platform or device they choose to use. This vendor-independent approach not only simplifies the delivery process but also strengthens the company’s position in the market, as it can adapt to changing technological landscapes and customer demands without being tied to proprietary solutions.

Why Unity Over Unreal for realvirtual.io

The decision not to use Unreal as a base for realvirtual.io at the moment is based on several factors. Firstly, the licensing costs for Unreal Engine may not be as economically attractive, considering Unity’s business model, where the delivered end customer digital twin is clearly free of license costs. Secondly, Unity’s user-friendly interface, C# scripting capabilities, and extensive availability of information and resources make it more approachable for developers and engineers. This familiarity and accessibility contribute to faster development cycles and easier integration of complex simulations.

Moreover, Unity’s established ecosystem, which includes the Asset Store and active community support, provides a wide array of pre-built assets, plugins, and tools that expedite development and address various challenges. This ecosystem has contributed to Unity’s success in various industries, including industrial simulation and engineering.

The Way Forward

The shift toward game engines in industrial simulation isn’t just about better graphics—it’s about fundamentally changing how we create, distribute, and maintain digital twins. Unity’s approach offers the right balance of performance, flexibility, and freedom that industrial applications demand. As the market continues to evolve, the winners will be those who can deliver real value to customers without locking them into expensive, proprietary ecosystems.