Digital twins: innovation and the future combined
Do you want to get the maximum digital added value out of your products? With Digital Twins, MaibornWolff offers you comprehensive services that enable seamless integration and optimization of your systems. Benefit from precise real-time data, individual application development and in-depth analyses that improve your decision-making processes and give you a clear competitive advantage.
We offer solutions
We implement comprehensive digital twin solutions that enable companies to accurately visualize and control their physical assets and processes virtually.
Our technologies capture, analyse and visualize real-time data to support informed decision-making and optimization.
How we achieve our goal
Data is collected by sensors, processed asynchronously via an IoT platform, aggregated and persisted in the backend and displayed in real time in the frontend. An adapter layer enables integration into existing systems. Security is ensured by a roles and rights system. Success is measured using defined KPIs.
This is our key
Our solutions are tailor-made, flexible and scalable so that they can be optimally adapted to the specific requirements of each customer. Through a holistic approach and a clear focus on customer needs, we create real added value and sustainable efficiency gains.
Our references & projects
A reference is worth more than 1,000 words. Fortunately, we have dozens of them. Click through a selection of our most exciting projects and see for yourself!
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MAN: Efficient threat analysis for control unitsLearn more
Digitalization increases cyber risks - especially for MAN's new CM4 control unit. Our experts use the 4×6 methodology and ThreatSea to identify threats at an early stage and develop targeted protective measures. Find out how MAN uses intelligent risk analysis to strengthen the security of its vehicles.
MAN: Efficient threat analysis for control unitsLearn more7 monthsProject duration
Over 20 workshopsThreat analyses
Over 500Potential risks evaluated
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Siemens: AI demand prediction platform for industrial production planningRead more
Siemens is looking to the future with the AI Demand Prediction Platform. Thanks to machine learning and AutoML, precise demand forecasts can be created for over 100 products and production can be better planned. Launched as a proof of concept, the platform quickly developed into a system that can be used productively. The self-service web application will soon be used in other plants.
Siemens: AI demand prediction platform for industrial production planningRead moreProject durationSince February 2022
Proof of conceptin a few weeks
Time series predictionfor 100 different products
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TÜV NORD GPT: Development of AI assistanceRead more
Find relevant information faster by chatting with documents? It's possible! The TÜV NORD GROUP uses GPT technology in the secure Microsoft Azure Cloud. With the aim of optimizing knowledge management and efficiency. The system enables new usage options within the testing group and is operated securely. Find out more about the innovative AI assistance system now.
TÜV NORD GPT: Development of AI assistanceRead moreProject durationsince September 2023
33.000GPT applications in the first month
ChatGPT Model 4in the European Microsoft Azure Cloud
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Schöck components: Improvement of the requirements processRead more
Together with MaibornWolff, the construction industry specialist optimized the requirements management of its Scalix design software. Thanks to the digital design approach, the technical requirements were re-specified and the software was further developed in a user-centered manner. The aim is to continuously increase user satisfaction and integrate internal and external interests. Read more about the methodology and results now!
Schöck components: Improvement of the requirements processRead moreProject durationsince 2022
Team size2-3 Digital Designer:inside
In 2024Scalix replaces old software -
VW: Digitization of key production figures with the iProcess appRead more
Less paper, more efficiency: Volkswagen replaces analog processes with the iProcess app. Cloud-native technologies and digital design enable intuitive recording and analysis of key production figures. This increases transparency and overall equipment effectiveness and paves the way for predictive maintenance at the automotive group.
VW: Digitization of key production figures with the iProcess appRead moreProject durationSince January 2021
Team size5 to 10 persons
Fast app developmentthanks to Digital Design
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DER Touristik: Become a digital travel companion in 7 monthsRead more
Travel information, bookings, support - all in one app. With Flutter, MaibornWolff developed a cross-platform solution for DER Touristik. In just seven months, a stable app was created for iOS and Android that supports multiple brands, languages and countries. This is how customer proximity travels.
DER Touristik: Become a digital travel companion in 7 monthsRead more7 monthsFrom Kickoff to Go Live
iOS and AndroidDigital travel companion
Whitelabelling solutionUncomplicated integration of additional brands, languages and countries
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Mixed reality: driving a real car in a virtual worldRead more
Virtual racing in a real car? MaibornWolff made it possible for the BMW M. Within three months, we used Unreal Engine 4 to develop a prototype that processes vehicle signals with high performance and creates an immersive driving experience without motion sickness. The cockpit remains real, the surroundings become the racetrack.
Mixed reality: driving a real car in a virtual worldRead more<3 monthsFrom the vision to the prototype
3D applicationsin real time
TeamUnreal development, XR technology, game design, smart devices, 3D content
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KUKA: Web interface for a new Human Machine InterfaceRead more
Rethinking robotics: KUKA is working with us to develop iiQKA.OS - an operating system with an intuitive web HMI. Using web technologies and scrum methods, we enable flexible customization and simple control. Open collaboration makes robotics more accessible than ever before.
KUKA: Web interface for a new Human Machine InterfaceRead moreGoalReplacing the current control software
iiQKA.OSFast and intuitive development
> 11,000 hoursProject work
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STIHL: Control iMOW robotic mower via appRead more
Robot mower redefined: The iMOW from STIHL makes lawn care smarter. Our software expertise combined with STIHL's hardware know-how ensures intuitive app control. The result? A networked device that makes gardening easier - simple, efficient, innovative.
STIHL: Control iMOW robotic mower via appRead moreProject durationsince August 2020
Robot mowerControl via app
Process optimizationwith the customer
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DEKRA: Modern enterprise architecture thanks to co-creationRead more
New IT for a sustainable future: the global auditing group needed to modernize its IT landscape. Co-Creation created a harmonized architecture and the EA Community promotes cross-border exchange for strong IT until 2025 - and beyond.
DEKRA: Modern enterprise architecture thanks to co-creationRead moreMost important method:Building an EA community
Created conceptEnterprise Architecture
Cooperationat eye level
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Miele domestic appliances are networked worldwideRead more
How do household appliances become smart? Miele relies on an IoT platform that we played a key role in developing. Container-based architecture ensures stable communication, DevOps for continuous improvement - so that smart appliances can be found in millions of households worldwide.
Miele domestic appliances are networked worldwideRead moreProject durationsince 2016
Success factors:High availability and scalability
IoT platformwith container-based architecture
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MAN: Secure Software Development Life CycleRead more
Trucks are networked - and therefore unfortunately also targets for attack. With SSDLC, MAN relies on security by design and integrates the highest security standards directly into development. Together with 22 teams, we have established security measures that go beyond the legal requirements.
MAN: Secure Software Development Life CycleRead more22 monthsProject duration
UNECE R155successfully integratedMethodsSecurity Champions, DevSecOps, OWASP SAMM
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It's LOS: Building a cloud-based low-code applicationRead more
Democracy meets digitalization: For "Es geht LOS!", we developed a low-code app for candidate management in five weeks. Built on AWS, it enables secure draws and efficient user management - for more citizen participation digitally.
It's LOS: Building a cloud-based low-code applicationRead moreProject durationSince the beginning of 2022
MVPin only 5 weeks
TechnologiesAmplify, AppSync, CodeCommit, IAM, Cognito, DynamoDB, Lambda
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Monitoring alarms in industrial plantsRead more
Safety in industrial plants requires a real-time overview. We developed a live monitoring platform that networks measuring devices and collects data via Azure IoT and Kubernetes. A scalable MVP was created in just three months: alarms appear in under ten seconds thanks to automated data acquisition via smartphone and Bluetooth.
Monitoring alarms in industrial plantsRead more3 yearsProject duration
<3 monthsto the MVP
Cloud migrationModernization & relocation -
Planning systems: Optimizing the capacity utilization of pressing plantsRead more
Maximum capacity utilization, minimum costs: Our customer relies on a central planning system for pressing plants. We have been supporting its further development with .NET Core, GraphQL and PostgreSQL for over ten years. Now the journey is moving to the cloud - for greater scalability, flexibility and efficiency.
Planning systems: Optimizing the capacity utilization of pressing plantsRead more>10 yearsCustomer support
Technological modernizationCloud-ready platformEfficiency through dataSite-specific cost planning -
Global workforce planning systemRead more
How do you achieve globally harmonized workforce planning? With a modern web application based on domain-driven design and hexagonal architecture. Event sourcing ensures transparent traceability, while Azure and Quarkus provide stability and scalability. The result: a flexible, future-proof solution.
Global workforce planning systemRead moreTeam sizeUp to 8 employees
Domain Driven DesignDevelopment approach
Microsoft Azure Cloudallows easy roll-out of new versions
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DER Touristik Online: Development and migration of a multi-client capable travel booking platformRead more
Different brands, one platform: DER Touristik merges several independent websites. We are supporting the migration to the AWS cloud with digital design, microservices and testing. The focus is on performance, SEO and UX - for a seamless digital travel experience.
DER Touristik Online: Development and migration of a multi-client capable travel booking platformRead moreStandardized platformMulti-client travel portalQuality assuranceEnd-2-End test automationCloud transformationMigration to AWS cloud -
KUKA: UI/UX design for an app for load data analysis for industrial robotsRead more
How do you reduce support requests? With a smart UX! KUKA and MaibornWolff developed a web-based application for load data analysis. Through "Understand/Build/Learn" we recognized challenges early on and validated solutions for an intuitive user experience.
KUKA: UI/UX design for an app for load data analysis for industrial robotsRead moreMethodProduct Experience Design
Customer requestEasier interaction between users and the system
Our goalOptimized load data analysis, fewer support requests, higher satisfaction -
BMW Group: Replacement of a production-critical legacy systemRead more
20-year-old system, new digital future. We gradually migrated production software to a flexible architecture. After two years, central plants were running on the new solution - stable, fail-safe and ready for the challenges of tomorrow.
BMW Group: Replacement of a production-critical legacy systemRead moreProject durationMid-2018 to the beginning of 2024
Team size25 employees
Legacy systemreplaced after 20 years
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BMW Group: Virtual reality brings vehicle design to lifeRead more
From the first draft to series production - BMW uses VR to visualize the entire development process. Based on the Unreal Engine, a uniform platform visualizes designs and processes. This saves on hardware prototypes and enables location-independent collaboration. MaibornWolff plays a key role in driving the development and integration of these VR use cases.
BMW Group: Virtual reality brings vehicle design to lifeRead more3.2 yearsProject duration
CooperationLocation-independent and virtual
InfrastructureScalable and expandable thanks to the cloud
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BMW Group: Remote software upgrade for vehiclesRead more
No visits to the workshop, no stress - thanks to Remote Software Upgrade, BMW vehicles worldwide remain up-to-date "over-the-air". MaibornWolff has been developing and operating the backend for secure updates for over three years. Microservice architectures and DevOps approaches guarantee stability, performance and security.
BMW Group: Remote software upgrade for vehiclesRead more5 yearsProject duration
Millions of vehiclesreceive new features thanks to "over-the-air" upgrade
IT securityAlways up-to-date thanks to remote software upgrade
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Creditreform: Secure proof of identity on the webRead more
Verifying online identities in a forgery-proof manner while maintaining user-friendliness - CrefoTrust makes it possible. Together, we developed a solution that creates trust with blockchain technology and proofs of concept. Personal and company data remain protected, while verifications run smoothly.
Creditreform: Secure proof of identity on the webRead more5 yearsProject duration
Pilot testsbased on several PoCs
Decentralized identityallows tamper-proof storage of identities and company information
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Bayernwerk: Knowledge management via teamsRead more
Experience must not be lost - Bayernwerk digitizes the knowledge of long-standing employees. MaibornWolff designed an intuitive MS Teams app with a clear UX/UI. Close collaboration, lived Scrum values and user-centered development make the app a success. Promoting exchange, optimizing processes - this is how knowledge transfer works today.
Bayernwerk: Knowledge management via teamsRead more6 monthsProject duration
Target:Identify implicit knowledge
Requirements:a user-centered, intuitive and clear UX/UI design
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Weidmüller: Progression of the Industrial Service PlatformRead more
IoT meets agility - Weidmüller and MaibornWolff developed the easyConnect platform for remote access, data visualization and machine learning. After intensive exploration, an MVP was created, accompanied by a cross-functional Scrum team. Making Industrial IoT smarter and more efficient.
Weidmüller: Progression of the Industrial Service PlatformRead more12 monthsup to the MVP
8 weeks analysisof professional, technical and organizational factors
Innovative portalfor end-to-end solutions
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SMA: Development of a Web UI for ennexOS platformRead more
Optimizing energy flows, reducing costs - we have been developing the Web UI of the ennexOS platform with SMA Solar Technology since 2016. It digitizes energy management processes for over a million users and combines smart solutions for a sustainable energy future.
SMA: Development of a Web UI for ennexOS platformRead moreProject durationsince 2016
> 1.000Modules and components in ennexOS platform
> 7.000Fuse tests
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digikoo GmbH: Apple Vision Pro for city plannersRead more
Planning cities smarter: Together with TUM, we developed the 3Digipad for Apple Vision Pro. It visualizes complex energy data in 3D and makes scenarios intuitively tangible. Dynamic building data and KPIs support urban planners in making sustainable decisions.
digikoo GmbH: Apple Vision Pro for city plannersRead more4 monthsProject duration
3D map with KPIsDisplay building data dynamicallyEnergy dataImmersive visualization -
digikoo: A data platform for the Azure CloudRead more
Structured geodata, automated quality assurance, seamless provision - we developed a powerful Snowflake data platform on Azure for Digikoo. It makes analysis easier for data scientists and lays the foundation for precise forecasts and new use cases.
digikoo: A data platform for the Azure CloudRead more5 monthsProject duration
Climate changePlan digitally and implement efficiently
Foundation data platformMicrosoft Azure Cloud

Sensors
The actual status (e.g. of water, electricity and heat output) with all relevant parameters is read out in real time via sensors and device interfaces.)
Actuators
Control of all elements such as heating, air conditioning or shading.
Networking
Connection of the sensors to a cloud platform to ensure reliability and remote access.
User interface
All data and functions at a glance in an intuitive user interface: Digital Twins offer convenient reporting and control functionality that supports people in their tasks.
Aggregation
Recording and evaluation of all resulting data for simulation, comparison and historical observation.
Virtual worlds optimized for real: Where are Digital Twins used?
From the manufacturing industry to urban planning, digital twins are used in a wide range of industries and applications. With the virtual representation of real processes and objects, digital twins enable precise analyses and fast, well-founded decisions.

Asset tracking and management
Real-time monitoring and management of mobile devices and assets, which record information such as location, status and usage, significantly increases efficiency and safety. On a large construction site, for example, data can be collected from construction machinery and tools, including location, operating hours and maintenance status. This information enables continuous monitoring of the current condition and usage of assets, which not only helps to optimize the use of resources, but also significantly reduces the risk of loss and theft.
Process optimization
By simulating and analyzing production processes, bottlenecks can be identified and efficiency increases can be achieved, which both increases productivity and reduces operating costs. Digital twins can be used in a production plant to virtually map and analyze the entire production process. For example, data on material flow, machine utilization and production times are recorded and evaluated in real time. These simulations make it possible to precisely identify inefficient processes and bottlenecks. On this basis, targeted measures can be taken to optimize production processes.
Monitoring and control
By using digital twins in a large refrigeration system, compressors and refrigeration units can be monitored and controlled in real time. Data such as temperature, pressure and energy consumption are continuously recorded and analyzed. This real-time monitoring makes it possible to adjust operating parameters immediately in order to optimize processes and cooling performance and minimize energy consumption. This improves the efficiency of the cooling system and makes the control of the appliances more precise and effective.
Predictive maintenance
By continuously monitoring and analyzing machine data such as vibration, temperature and operating hours, maintenance requirements can be identified and predicted at an early stage. On a CNC machine, this real-time data makes it possible to identify signs of wear or impending failures so that maintenance measures can be planned in a targeted and timely manner. This leads to a reduction in downtime and maintenance costs.
Supply Chain Management
The use of real-time data and simulations to monitor and optimize the entire supply chain allows for a significant increase in transparency and efficiency. In a global production company, digital twins enable seamless monitoring of the supply chain, from the procurement of raw materials to the delivery of end products. Data on stock levels, transport times and production capacities are recorded and analyzed in real time. This allows bottlenecks and delays to be identified and rectified at an early stage. These measures not only improve the transparency and efficiency of the supply chain, but also reduce operating costs and increase customer satisfaction.
Fleet management
Real-time monitoring and analysis of the vehicle fleet, including engine performance, fuel consumption, maintenance requirements and current location, enable fleet operations to be optimized and wear and tear to be reduced. A construction company can use digital twins to monitor construction equipment such as excavators and bulldozers. Data on engine performance, fuel consumption, operating hours and location are continuously recorded and analyzed. This real-time information makes it possible to identify maintenance requirements at an early stage and use the machines efficiently, which leads to a reduction in wear and tear, improved capacity utilization and lower operating costs.
Energy consumption optimization
Monitoring and analyzing the energy consumption of systems and buildings offers the opportunity to identify potential savings, reduce energy costs and improve sustainability. In a data center, digital twins can be used to monitor the energy consumption of servers, cooling systems and other critical infrastructure in real time. Data on power consumption, cooling performance and server utilization is continuously collected and analyzed. This real-time monitoring helps to identify inefficient usage patterns and take measures to optimize energy efficiency. This reduces energy costs and significantly increases the sustainability of data center operations.
Facility management
The management and optimization of building operations and maintenance can be effectively controlled through real-time monitoring and analysis of building data, resulting in reduced operating costs and improved building performance. In a modern office complex, digital twins can be used to monitor the operation and maintenance of the building in real time. Data on heating, ventilation, air conditioning (HVAC), lighting and security systems is continuously collected and analyzed. The result: reduced operating costs and improved overall building performance.
Product development
Simulating and testing new products in a virtual environment makes it possible to identify problems in development at an early stage. This shortens development cycles and reduces costs. In the development of new electric vehicles, digital twins are used to simulate and test the design and performance of batteries and drive systems. These simulations help to identify potential problems such as overheating or inefficient energy distribution at an early stage so that adjustments can be made before physical prototypes are built.
Digital Twins: Procedure
Our approach to implementing Digital Twins is based on careful analysis and clear objectives. Every step is designed to deliver customized solutions that are perfectly tailored to our clients' needs. From planning to implementation, we follow a structured and proven process. This methodical approach ensures that each Digital Twin solution is effectively integrated and optimally utilized, creating real value for our clients.

Requirements analysis and planning
The first step in implementing a project is to clearly define objectives and use cases. The relevant stakeholders are then involved in order to identify their needs and requirements. This is followed by an analysis of the existing systems and framework conditions. On this basis, the technology selection is made, whereby suitable sensors, IoT platforms, backend systems and visualization tools are determined.
Data integration and acquisition
The next step in the project involves data modeling, in which a data model for the digital twin is planned and implemented. This is followed by the data connection, in which sensors, actuators and device interfaces are connected to the platform and the data is recorded. To ensure the integrity of the recorded data, mechanisms for validating and cleansing the data are defined to ensure high data quality.
Implementation
Another important step is the design and interaction concept, in which a consistent and human-centered user experience is developed. At the same time, the backend or cloud infrastructure is set up to implement the data processing logic, aggregation and persistence. The front end is then developed, creating user interfaces for visualization and interaction. Finally, security measures are integrated, including a roles and rights system and data protection measures to ensure the security and protection of the data.
Testing and optimization
A key part of the project is to carry out system tests in order to regularly and comprehensively check functionality, performance and security. At the same time, feedback from users and stakeholders is continuously collected and analyzed. Based on this feedback and the key performance indicators (KPIs), adjustments and optimizations are made to ensure continuous improvement of the system.

With a digital twin, we get the maximum digital added value out of our customers' products.
Digital Twin: Workshop
In a two-day workshop, we jointly evaluate the general feasibility of your Digital Twin project and outline a rough plan for implementation. During this workshop, we analyze the needs and goals of your company as well as the environment in which the Digital Twin is to be embedded. In the workshop you can expect
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Introduction to the concepts of digital twins and technologies
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Evaluation of the relevant use cases in the company
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Analysis of the interfaces and environment in the company
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Development of a rough project plan and the most important milestones
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Definition of risks and success criteria
The aim of the workshop is to create a clear understanding of the feasibility of Digital Twin projects in your company. You will receive a rough plan and concrete next steps for implementation based on your company's specific requirements and resources.