Digital Twins: Powering the Next-Generation of Industrial Growth

The Digital Surge

The industrial metaverse is accelerating at a breakneck pace, with forecasts indicating a leap from $28.7 billion in 2024 to a staggering $228.6 billion by 2029, as reported by market research platform MarketsandMarkets. What does this mean for businesses? According to industry experts, the industrial metaverse is expected to add $100 billion in revenue by 2030, far outpacing the consumer and enterprise segments (Deloitte).

To translate this vast market potential into real-world value, Tech Mahindra is redefining the product-price-performance equation with a high-fidelity digital twin. Powered by immersive simulations, automation, and real-time analytics, our solutions mirror complex industrial settings, enabling clients to validate designs, predict maintenance needs, and accelerate time-to-value.

Adoption Accelerators / Trends Shaping the Shift

The industrial metaverse is shifting from pilot projects to core operations, driven by the convergence of digital twin, AI, and IoT. As adoption accelerates, businesses are focused on quantifying return on investment through real-world outcomes. The most prominent trends are highlighted below:

• Uptake of Digital Twin: More companies are making strategic investments in digital twins to achieve operational excellence. Gartner predicts that by 2027, over 40% of large enterprises will leverage this technology for revenue growth.
• Integration of AI/ML: Pairing AI/ML with digital twin enables predictive analysis and automation, helping companies to reduce costs, speed up deployment, and deliver significantly more business value.
• Greater Network Bandwidth: 5G’s low latency and high throughput enable high‑resolution visuals and seamless multi‑user collaboration in remote or harsh environments, making immersive industrial metaverse experiences possible.
• Focus on Sustainability: Rising energy costs and stricter ESG mandates prompt companies to optimize simulation workloads and resource allocation. They are leveraging GPU virtualization and scheduling compute during periods of renewable energy availability to reduce their carbon footprint.

Driving Scalable Impact: Tech Mahindra’s Industrial Metaverse Leadership

To meet the rising global demand for enterprise-grade digital twin solutions, Tech Mahindra has partnered with NVIDIA to launch a dedicated Center of Excellence (CoE), powered by the Omniverse platform. This CoE seamlessly connects high-fidelity digital twins with physical assets to run advanced simulations and analytics across diverse sectors, including manufacturing, automotive, telecommunications, healthcare, banking, financial services, and insurance.

Through the CoE, our clients gain on‑demand access to skilled resources, domain expertise, and cutting-edge industrial solutions. These capabilities help maximize ROI and reduce unnecessary operational costs across their businesses.

From Blueprint to Business Impact

From optimizing manufacturing operations to transforming telecom networks, Tech Mahindra’s industrial metaverse and digital twin suite, built on Omniverse, assists businesses to lead in an ever-evolving digital world. Let’s take a look at some of our solutions designed for the telecom and manufacturing industries in the space.

1. Radio Frequency (RF) Propagation for Signal Strength and Coverage Testing

Client Challenge

A major European operator faced multiple hurdles in designing, deploying, and maintaining its radio network:

• Diverse infrastructures (towers, fiber routes, and radio equipment) exist across various systems, making holistic management difficult
• Discrepancies between physical infrastructure and recorded data create planning errors and operational inefficiencies
• Relying on estimation extends rollout timelines and hinders precision
• Predicting signal behavior and network performance in varied terrains is challenging, resulting in coverage gaps or interference
• Reactive maintenance leads to service disruptions and customer dissatisfaction
• Analyzing network performance in real-time is difficult

TechM Solution

We conceptualized and developed a solution that combines three use cases: Infrastructure Reconciliation, Network Planning and Rollout, and Real-time Maintenance and Operations.

It enables the accelerated and templatized photorealistic 3D modeling of tens to thousands of antennas, each precisely mapped to its real-world location in a virtual environment. Users gain complete operational control and can run network simulations with synthetic data and real‑time analytics driven by continuous data streaming.

A look at the steps below:

Key Benefits

• Accurate asset records with minimized discrepancies
• Enhanced maintenance planning and execution
• Accelerated network deployments
• Reduced costs through optimal resource allocation
• Improved network connectivity and coverage
• Restricted service disruptions

2. Automotive Design Simulation and Rendering

Client Challenge

A leading Indian automotive manufacturer lacked an integrated, collaborative design workflow, which led to:

• Siloed multi-source sequential process, with no context for engineers across the design lifecycle
• Multiple versions of the same file result in long lead times and a lack of simulation visibility
• High costs and inefficiencies due to reliance on physical clay models across numerous design iterations

TechM Solution

We developed a solution that leverages NVIDIA Omniverse for real-time design collaboration between engineers from remote locations, significantly reducing production costs. By providing a single source of truth, Omniverse ensures consistency as the car model progresses through design, engineering, simulation, and rendering phases.

Key Benefits

• Real-time, collaborative environment for designers
• Faster iterations and improved design creativity
• Significant cost savings and reduced reliance on physical prototypes
• Scalable design workflows with on-demand resource allocation
• Better product and faster time-to-market

The Road Ahead

The function of the industrial digital twin is expanding, moving past simple monitoring and simulation. It will be defined by autonomous operations, deep integration with Generative AI, and a broader scope of enterprise-wide applications, giving rise to the concept of the ‘Twin of Everything’. Here, dynamic replicas extend beyond the factory floor to model entire ecosystems, such as cities, human organs for predictive healthcare, and global weather patterns for risk management.

This push for standardization unlocks their true potential: to become active participants who directly guide and control physical operations. This shift is set to drive unprecedented efficiency, innovation, and sustainability across the industrial landscape within the next 18 to 24 months.