Bridging the Physical and Virtual: Digital Twin Solutions with Arduino and FlexSim

Process simulations are used in modern industries, enabling the optimization of operations, reduction of costs and risks, enhancement of decision-making, and promotion of innovation. By experimenting with scenarios, adjusting variables, and predicting outcomes without requiring costly or risky physical tests, simulations provide valuable insights into complex phenomena, supporting behavior prediction and informed decisions. Digital twins take simulation a step further by creating dynamic, real-time virtual representations of physical systems or processes, facilitating a deeper understanding of their performance. These digital twins not only improve the efficiency and sustainability of products and processes but also enhance competitiveness in an increasingly digitalized world. This study emphasizes the importance of simulations and digital twins by presenting a practical approach using FlexSim software and Arduino technology. FlexSim’s robust simulation capabilities, combined with Arduino’s accessibility, provide a cost-effective and scalable solution for experimenting with interconnected physical and digital systems. This approach highlights essential principles of control, monitoring, optimization, and automation, offering a practical pathway to Industry 4.0 and advancing the digital transformation of modern industries.