Technology | What they Say
DIGITAL TWIN TECHNOLOGY: TRANSFORMING THE WIDE-FORMAT PRINT SECTOR
The high-volume commercial printing industry is pressured to modernise in an increasingly digital world where margins are tightening, environmental regulations are ever-evolving, and customers expect quick turnarounds with higher quality output. As a result, many print service providers are exploring new technologies that can help ensure operations are error-proof and ready to meet future demands. Digital twin technology, when integrated with artificial intelligence (AI), emerges as a key strategy for overcoming operational challenges. This innovation gives businesses control over complex printing systems through real-time monitoring, remote maintenance, predictive insights and immersive remote training. Used widely in sectors like aerospace, manufacturing and logistics, digital twin technologies paired with AI offer tangible benefits to the printing sector. This is particularly true for wide-format operations, where machine uptime and job quality are critical to operational success.
GILAD TZORI, COO OF
FRONTLINE.IO, OUTLINES HOW AND WHY THE WIDE-FORMAT PRINT SECTOR IS BEING TRANSFORMED THROUGH THE
UTILISATION OF DIGITAL TWIN TECHNOLOGY.
WHAT IS A DIGITAL TWIN? A digital twin is a replica of a physical asset, such as a printing machine, print engine or even an entire print line, represented in a virtual environment in augmented reality (AR) or virtual reality (VR) modes. The virtual model mirrors the real system’s behaviour, performance and operating conditions. It uses a complete parts catalogue to learn the machine and continuously updates based on incoming data, allowing users to simulate and analyse equipment remotely. In the high-volume printing industry, where machinery can be highly complex and specialised, digital twins are uniquely equipped to handle these intricate systems.
Using digital twin technology accessible across extended reality (XR) platforms, manufacturers can rapidly convert existing CAD files into interactive 3D simulations across AR, VR, desktop, tablet and mobile devices. This process is generally complex and tedious, often taking days to weeks or even longer for highly intricate designs. Through a specialised XR training and remote support platform, like
frontline.io, HP creates and deploys content across global teams five times faster than traditional content creation methods. This cross-device compatibility and quick conversion make it easier for print companies to provide accelerated, scalable training and support solutions for their teams.
INDUSTRY CHALLENGES THAT DEMAND CHANGE Operational challenges affect printing businesses from top to bottom, impacting everything from efficiency and profitability to workforce competency and market competitiveness. Downtime is expensive, misprints can lead to customer dissatisfaction and unscheduled service visits are disruptive. Preventative maintenance routines often rely on manual checks, consuming technician hours and leading to inconsistent results that may require further inspections. Furthermore, traditional materials, such as PDFs become outdated and lack the interactivity needed to engage today’s workforce. Digital twin
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technology can allow printing companies to quickly create, update and deploy interactive content, ensuring that reference material is always current and relevant. The search for skilled recruits can also greatly impact a business’s operational efficiency. As experienced technicians retire or move into other roles, onboarding new hires quickly and safely can be challenging. Traditional training methods require physical machines and time-consuming shadowing, which can delay productivity and widen the knowledge gap. By enabling new hires to pause, repeat and explore procedures at their own pace, these virtual simulations provide access to crucial hands-on experience, ensuring the workforce is adequately prepared. Beyond operational efficiency, sustainability represents a critical priority that demands immediate attention. Waste reduction and carbon-friendly practices are increasingly important to customers and regulators alike. Companies are increasingly becoming corporate citizens, and the need to overhaul wasteful operations is paramount. Remote training and support powered by digital twin technology are crucial in achieving this sustainability goal. Operational support becomes readily available regardless of location, thus eliminating any distance-related hurdles or inaccessibilities. Additionally, by effectively addressing quality inconsistencies, misprints and repeated calibration runs, companies can decrease material waste and energy consumption, improving their environmental impact.
REMOTE TRAINING AND SUPPORT WITH EXTENDED REALITY
Using XR tools, such as augmented reality (AR) or virtual reality (VR), with software that performs digital twins, allows new staff to train on complex print equipment in a safe and fully simulated environment. This approach eliminates expensive, dedicated training machines, reduces travel costs to distant training sites and avoids the need for onsite trainers. Printing providers can choose XR training platforms that function seamlessly on headsets, tablets, PCs and mobile phones, allowing organisations to modify training across field teams, production lines and remote facilities with limited infrastructure.
A 2022 study found that VR learners trained with VR
were up to 275% more confident in their ability to act on what they learned after training. For print service providers, this enhancement can translate into faster onboarding, less rework due to user error and fewer disruptions to production environments.
In a sector where hands-on experience is critical but access to live equipment is limited, digital twins offer a scalable solution that improves accessibility. Trainees can run diagnostics, replace parts and resolve simulated errors as they would in a real-world scenario. Employees gain confidence in the skills gained through interactive training, allowing for more integrated and less disruptive workflows.
In addition to training, XR solutions also offer useful remote support. Technicians and operators receive
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