Technology | What they Say
real-time, guided assistance from remote experts through the same XR-enabled digital twin environment. This removes the need for on-site visits, speeds up problem solving and allows experts to provide clear, step-by-step instructions from any location. This combination of remote training and support enables teams to perform at their best, no matter where they are while minimising downtime and maximising operational efficiency.
PREVENTATIVE MAINTENANCE WITH REAL-TIME PARTS MANAGEMENT
High-volume printing machine maintenance has traditionally been reactive or scheduled on rigid timeframes. Since printing machines have various levels of complexity, pinpointing components that need check-ups or replacements can be time-consuming. Digital twins enable predictive maintenance by providing access to comprehensive, up-to-date parts catalogues. The digital twin technology that
frontline.io pioneers with large-scale 3D models includes up to 200,000 parts. Having this level of detail and accessibility through an organised, real-time catalogue of parts gives maintenance teams accurate information about the specific components that need attention. With this crucial data in one place, operators can identify and source the right parts, minimising downtime and preventing delays caused by outdated or missing information. According to a 2025 study, predictive maintenance is emerging as a crucial tool that significantly improves manufacturing processes’ sustainability and efficiency. These benefits are relevant in the high-volume segment, where servicing large, specialised devices can be costly, slow, and taxing.
Simulating different maintenance scenarios also helps
operators enhance resource allocation. Detailed, precise insight into replacement parts that require attention provides remote support with the confidence to resolve the issue effectively. This also limits wasted resources and time on in-person diagnostics, providing a more carbon-friendly approach.
OPTIMISING WORKFLOWS AND ENSURING QUALITY Digital twins allow print service providers to increase press availability, quickly upskill operators and reduce their carbon footprint through remote-first service models. Through immersive XR guidance, companies have significantly reduced the need for formal operator training and the time spent creating and deploying scalable content across global teams, supporting growth goals. Visual remote assistance through digital twin technology allows technicians and operators to receive real-time, guided support from remote experts, eliminating costly on-site visits and speeding up maintenance resolution. For training, immersive learning environments powered by digital twins provide new staff with hands-on experience without needing dedicated training machines or travel to physical sites. This combination significantly reduces support and training expenditures, contributing to overall profitability, sustainability and operational excellence.
A LOOK TOWARD THE FUTURE The printing sector is evolving to a new phase defined by data, simulation and smart automation. CIOs and CTOs in wide-format printing must evaluate readiness and current bottlenecks and explore how these technologies can revolutionise their current infrastructure. The early adopters will see operational gains and be a step ahead in the global shift to transformative digital solutions.
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