AAS you wish: The Digital Twin in Industrial Applications

The digital twin is already present in various forms across a wide range of industrial markets. Yet, this “hidden champion” of the digitalization megatrend has not quite achieved its full breakthrough. Asset Administration Shell (AAS) offers innovative technology that could enable just that: the seamless exchange of virtually all digitally available information about a physical product. But how can digital twins already be used profitably today? Can they even support the sales process? And where do the technical limitations of digital twins lie?

1.1. Why the Digital Twin Is Becoming Increasingly Important

The rapid proliferation of various AI models and agents in everyday life has further accelerated digitalization in the industrial sector. In the shadow of the ongoing hype surrounding artificial intelligence, the digital twin is steadily making its way into a wide range of industrial domains. In a world that is changing at breakneck speed, business processes must also be reimagined. The digital twin opens up the vision of a fully connected reality - one in which information is no longer maintained manually, but is instead generated, updated, and shared automatically across organizational boundaries. Data no longer exists in isolation but converges centrally. This relieves employees of the burden of maintaining information and allows them to focus on valuecreating activities.
The European Union is also increasingly emphasizing the relevance of digital twins. New regulations and directives are being introduced at regular intervals, and their requirements can be met more comprehensively through standardized digital twins. For example, the specifications of the Digital Product Passport (DPP), as outlined in the Ecodesign for Sustainable Products Regulation (ESPR), can be implemented using digital twin technology.¹ The digital twin also plays a role in the context of the Cyber Resilience Act (CRA): It can provide security-relevant information - such as notifications about available patches - and inform customers that these updates should be applied via the accompanying software.²

Digital twins can already significantly reduce the effort required to search for and provide product information. One example: a single QR or data matrix code on a asset can provide access to all relevant information about the installed components. A service technician can retrieve the operating manual on-site-without a special app or locally stored documents-and immediately access the necessary information
The digital provision of such information is also a key step toward meeting the requirements of the Digital Product Passport, as mandated by the Ecodesign for Sustainable Products Regulation (ESPR) under the EU Green Deal.
Digital twins can also greatly enhance customer experience. In our private lives, we are used to having all the information about a product or order available centrally and at any time. A customer portal based on a digital twin can deliver exactly that-because the required information already exists in digital form and can be utilized accordingly.
Another exciting area of application is the secure sharing of specific data. In principle, data belongs to the entity that generates it-in an industrial context, this is typically the operator of the machine or system. If both the machine manufacturer and the component suppliers use AAS-based digital twins, the operator can precisely control what data is shared, when, and with whom.
Just like a physical supply chain, a digital twin is delivered along with the product-and just as a drive is integrated into a machine, its digital twin is integrated into the digital twin of the overall system. This creates a complete digital twin of the machine, enabling the operator to manage data securely and easily. In short: the operator retains control over what is shared, when, and with whom.

Moreover, a standardized digital twin already significantly reduces integration effort today. Once an AAS interface has been implemented, any number of digital twins based on this technology can be quickly and easily integrated into existing systems-such as ERP, CPQ, or PIM systems. Even if the initial effort seems high, especially when developing the AAS Interface, it pays off with every additional integration: the process becomes noticeably faster and more efficient.

3.1. Use of the AAS-Based Digital Twin in the Pre-Sales Phase

The pre-sales phase focuses on customer acquisition and the precise identification of individual requirements that feed into solution development. This is precisely where the AAS-based digital twin can provide critical support by offering structured, standardized, and machine-readable product data even before a contract is signed.
Thanks to this digital product data, customers can integrate suitable components into their systems as early as the design phase. Various departments benefit equally:

»  Design engineers receive information on mechanical properties such as dimensions, mounting points, or weight.
» Software developers and electronics engineers gain access to data on voltages, interfaces, or communication protocols.


A real-world example illustrates this well: A manufacturer wants to check whether a new component is compatible with an existing PLC. The digital twin of the component provides all relevant information - such as communication protocols and electrical parameters - allowing the compatibility check to be performed automatically, without the need to contact technical support. Digital twins also play a vital role in the quotation process. Configuration and quotation workflows can be automated as follows: A customer configures their desired component using a configurator. Based on this configuration, a quote is automatically generated-including price, data sheet, and 3D model. The digital twin serves as the central data source, providing both commercial information (e.g., pricing) and technical data (e.g., bill of materials).
If the customer’s systems support an AAS interface, the digital twin can be directly imported and further processed. In the field of functional safety, the digital twin is becoming an indispensable tool in mechanical engineering. When safety-relevant information - such as SIL-/PL-values, failure rates, diagnostic coverage, or certification data - is made available in a structured and machine-readable format within the AAS model, the safety assessment of an entire system can be automated. This enables machine builders to calculate the required safety level during the design phase and identify potential weaknesses early on.

3.2. The AAS-Based Digital Twin in After-Sales: Added Value Through Transparency and Customer Focus

The digital twin based on the AAS reveals its full potential in the after-sales process, as it becomes linked to the real-world condition and behavior of a specific physical product. This enables targeted services, efficient maintenance, data-driven decisionmaking, and even new business models.
One particularly relevant area of application is maintenance, repair, and technical service. Current condition data - such as operating hours, error codes, or temperature trends - can be provided in a structured format. This information not only supports optimal planning of service operations but can also be processed further in industrial IoT systems. These systems can evaluate the condition of installed components based on the data and proactively inform operators of potential changes. The AAS-based digital twin thus actively contributes to optimal component utilization and supports the development of digital services such as predictive maintenance.
Another key use case is traceability in warranty and guarantee processes. The digital twin continuously documents events such as maintenance work, spare part replacements, or software updates - with timestamps and clear associations to serial numbers or assemblies. This simplifies recall campaigns, as affected customers can be specifically informed. Warranty claims also become easier to validate, as the digital twin can verify whether the product was operated correctly, maintained regularly, and equipped with original parts.
In summary, the after-sales process holds tremendous potential for the AAS-based digital twin. It creates transparency, enables automated workflows, improves customer communication, and opens up new service-oriented business models. Companies that strategically leverage this technology in after-sales can not only reduce costs but also significantly increase customer satisfaction and loyalty.

3.3. Is This the End?

This is just the beginning: In an increasingly dynamic and interconnected world where digital technologies continue to gain importance. The AAS-based digital twin is constantly opening up new possibilities. One particularly promising area is its contribution to the circular economy and sustainability. The better a product is digitally represented - structured and enriched with detailed information - the easier it becomes to disassemble, recycle, or reuse components at the end of the product lifecycle. Information such as

» Material composition
» Joining techniques
» Recycling instructions
» Historical stress data

can be documented in the digital twin and automatically evaluated. This makes circular processes more efficient - from disassembly to reuse.
Another forward-looking application is data-driven business models. With the help of the digital twin, models such as “payper-use” or “equipment-as-a-service” can be implemented. The foundation for this is the reliable and continuous recording of actual usage - such as operating hours, utilization, or location. The digital twin acts as a neutral and trustworthy source of information. Based on this, contracts can be dynamically structured, billing automated, and customer needs addressed more precisely.

The digital twin also plays an increasingly vital role in product development. During operation, the AAS collects usage data that - while respecting data protection regulations - provides valuable insights into real-world conditions, usage patterns, or weaknesses. This information flows directly into the development of new products, helping to make them more targeted, robust, and customer oriented. In this way, the circle closes: the digital twin becomes not only a mirror of the product but also a driver of innovation.