Digital twin software ‘brings the industrial metaverse to life’
7 January 2026 
Siemens has announced a software product that builds industrial metaverse environments, helping organisations to apply industrial AI, simulation and real-time physical data to make decisions virtually, at speed and at scale.
The Digital Twin Composer allows industrial users to combine 2D and 3D digital twin data with physical real-time information in real-time, photorealistic scenes. They can build and maintain these environments rapidly, containing all aspects of their product or production data (both virtual and physical) in a secure, managed 3D experience, throughout the lifecycle of the product, process or facility.
The software provides real-time insights and intelligence, allowing users to visualise, interact with, and iterate on, any product, process or factory in its real-world context before starting physical design or construction.
One pilot user, PepsiCo, is using the software to transform some of its US manufacturing and warehouse sites by converting them into high-fidelity 3D digital twins that simulate the plant’s operations and supply chains to establish a performance baseline. Within weeks, PepsiCo teams were able to optimise and validate new configurations to boost capacity and throughput, giving the company a unified, real-time view of its operations with flexibility to integrate AI-driven capabilities over time.
PepsiCo can now recreate every machine, conveyor, pallet route and operator path with physics-level accuracy, allowing AI agents to simulate, test and refine system changes. The company can now identify up to 90% of potential issues before any physical modifications occur. This has already resulted in a 20% increase in throughput for PepsiCo’s initial deployment, and is driving faster design cycles, almost total design validation, and 10–15% reductions in capital expenditure, by uncovering hidden capacity and validating investments virtually.
Siemens says that the Digital Twin Composer will reduce barriers that result from design, engineering and production teams working independently, and relying on different tools and disconnected data systems. The software combines design, simulation and operations into a single model that engineers can use to test products, processes and facilities within minutes, validate automation long before hardware exists, and operate products or facilities from the digital twin.
“The new Digital Twin Composer delivers on our vision for the industrial metaverse,” says Joe Bohman, executive vice-president of PLM Products at Siemens Digital Industries Software. “It helps manufacturers to overcome the unprecedented challenges of mastering complexity, accelerating production, reducing costs and increasing profitability. Siemens and Nvidia are partnering to help manufacturers bring the most complex products, processes and factories online faster, boost resiliency and sustainability, and continuously optimize performance.”
“In an era where every physical object and process will have a digital twin, Siemens’ Digital Twin Composer establishes a digital thread that connects the silos of design, engineering and operations across the Siemens Xcelerator ecosystem,” adds Rev Lebaredian, vice-president of Omniverse and Simulation Technology at Nvidia. “Enterprises can take advantage of physically accurate simulation across their workflows to validate their entire lifecycle – from product design to factory logistics – in the virtual world before committing a single atom to the real one.”
Digital Twin Composer is part of Siemens’ Xcelerator software portfolio, used by companies to develop digital twins for designing, simulating and preparing products, process and factories at speed and scale. The software connects photorealistic and physically accurate 3D digital twins to real-world physical data sources as such MES (manufacturing execution software), QMS (quality management systems), PLC code from machines, or data from factory assets or the IIoT (Industrial Internet of things).
Siemens announced the Digital Twin Composer at the Consumer Electronics Show in the US, where it demonstrated the new software being used in a robotic palletising application where digital twin analytics were optimising gripper performance and suction points dynamically.
