Digital Twin Statistics By Market And Facts (2026)

Introduction

Digital Twin Statistics: A digital twin is a live digital copy of a real object, machine, or system. It stays linked through sensors and software, so it updates in real time. Unlike a normal 3D model, it shows what’s happening right now and can predict what might happen next. With a digital twin, you can try new ideas safely, find issues early, reduce downtime, and improve performance.

Businesses use digital twins in factories, power plants, buildings, smart cities, and healthcare. As data and AI get stronger, digital twins are becoming a powerful way to run operations faster, safer, and smarter.

Editor’s Choice

1. The Global Digital Twin Market size is expected to reach approximately USD 36.8 billion by 2026.
2. Digital twins in construction and real estate help owners cut energy use up to 50% and reduce operating costs by about 35%.
3. About 63% of automotive companies are using digital twin technology to support their sustainability goals.
4. The digital twin market in healthcare was valued at USD 2.81 billion in 2025 and is projected to reach USD 3.68 billion by 2026.
5. The global automotive digital twin market is set to grow from USD 3.12 billion in 2025 to around USD 18.42 billion by 2031, at a strong 34.44% CAGR.
6. The electrical digital twin market reached USD 1,359.7 million in 2025 and is estimated to grow to USD 4,038.3 million by 2035.
7. System-prediction digital twins improve forecasting by 30%, helping reduce operational risk.
8. More than 75% of businesses have already adopted digital twin technology, and many are using it at least at a medium level of sophistication.
9. In 2025, digital twins were linked with 20%-30% better capital and operational efficiency in public infrastructure programs.
10. Interviews with senior R&D leaders indicate that digital twins can reduce total development time by up to 50%.
11. Digital twins are most commonly used to improve product quality (34%), reduce manufacturing costs in USD (30%), reduce unplanned downtime (28%), increase throughput (25%), and ensure safe manufacturing (24%).

Key Takeaways

• According to market.us, around 75% of companies using IoT already gain value from digital twins or plan to deploy them within the next year.
• Unilever has built an AI-enabled digital twin across 300+ factories, with potential annual savings of USD 2.8 million and productivity improvements of 1%-3%.
• 80% of engineers say VR adds more value when used alongside digital twins.
• 57% of firms consider digital twins important for improving sustainability, and this importance is likely to rise as ESG reporting demands increase.
• A global aviation company uses component digital twins and reports 99.9% accuracy in predicting anomalies in jet engine components.
• A manufacturing firm uses process digital twins to adjust production settings and has reduced defective products by 75%.
• An oil company uses digital twins to improve drilling operations and has achieved daily cost savings of up to USD 1 million.

Digital Twin Market Size

(Source: market.us)

• The Global Digital Twin Market size is expected to reach approximately USD 36.8 billion by 2026.
• The market is forecast to grow at a CAGR of 46.1% from 2024 to 2033, reaching USD 522.9 billion by 2033.
• According to Mind Inventory, digital twins in construction and real estate help owners cut energy use up to 50% and reduce operating costs by about 35%.
• Around 75% of large enterprises are investing in digital twin technology to scale AI solutions across their operations.
• In the oil and gas sector, applying digital twins to reservoir optimisation can improve oil recovery by about 5%-10%.
• By 2035, digital twins designed for personalised treatment are expected to lead adoption and account for nearly 29% of the market.
• About 63% of automotive companies are using digital twin technology to support their sustainability goals.
• Digital twins can speed up AI development and deployment by up to 60%, reduce operational costs by up to 15%, and improve commercial efficiency by about 10%.
• Organisations using digital twins have reported up to a 20% improvement in consumer promise fulfilment and around a 10% reduction in labour costs.

Digital Twins In Healthcare Market

(Source: mordorintelligence.com)

• The digital twin market in healthcare was valued at USD 2.81 billion in 2025 and is projected to reach USD 3.68 billion by 2026.
• Looking further ahead, it is projected to reach USD 14.12 billion by 2031.
• This implies a strong growth outlook, with an estimated CAGR of 30.86% over the 2026-2031 forecast period.
• By component, software platforms had the largest market share at 55.02% in 2025, while patient digital twin analytics is expected to grow the fastest, with a 35.2% CAGR through 2031.

Furthermore, other segmental analyses are stated in the table below:

In the Automotive Market

• According to TechSci Research, the global automotive digital twin market is set to grow from USD 3.12 billion in 2025 to around USD 18.42 billion by 2031, at a strong 34.44% CAGR.
• In June 2025, the BMW Group announced plans to roll out its virtual factory technology across more than 30 production sites.
• This wider rollout could cut production planning costs by up to 30%.
• Perforce’s March 2025 report says 57% of developers with less than one year of experience worry most about code complexity.
• In January 2025, Hyundai and NVIDIA expanded their partnership to build AI computing for digital transformation.
• According to Global Market Insights, around 92% of companies using digital twins achieved returns of over 10%, and more than half reported at least 20% ROI.
• In January 2026, Siemens launched Digital Twin Composer, a new software tool that makes it easier to build Industrial Metaverse environments.
• The U.S. passenger car digital twin market rose to USD 348.2 million in 2025, up from USD 306.5 million in 2024.
• The North American passenger car digital twin market is expected to grow at a 27.2% CAGR from 2026 to 2035, reaching USD 4.2 billion by 2035.

In Manufacturing

(Source: market.us)

• The Global Digital Twins in manufacturing market size is expected to be around USD 5.9 billion by 2026, up from USD 4.6 billion in 2025.
• The market will grow at a CAGR of 28.1% from 2025 to 2034, reaching around USD 42.6 billion.
• Expert Market Research further stated that North America is forecast to grow at a 35.4% CAGR and Latin America at 29.85% from 2026 to 2035.
• Meanwhile, India is projected to grow at 38.4% CAGR, Canada at 37.8% CAGR, while Germany held a 5.6% market share in 2025.
• Predictive maintenance at 37.3% CAGR, and large enterprises at 34.8% CAGR.

Electrical Digital Twin Market Statistics

(Source: futuremarketinsights.com)

• The electrical digital twin market reached USD 1,359.7 million in 2025 and is estimated to grow to USD 4,038.3 million by 2035.
• This reflects steady growth, with an expected 11.5% CAGR from 2025 to 2035.
• According to Expert Market Research, North America is projected to grow faster than the global average, with a 41.4% CAGR from 2026 to 2035.
• The USA is forecast to grow at a 42.6% CAGR, and India at a 42.4% CAGR over the same forecast period.
• Digital gas and steam power plant solutions are projected to reach a 40.9% CAGR, while the utilities segment is expected to grow at a 39.5% CAGR.

Most Common Digital Twin Applications

• A report published by iot-analytics.com stated that system-prediction digital twins (30%) forecast how large, connected systems may evolve, helping teams prepare and reduce operational risk.
• Digital twins (28%) model how a system will react in different situations, allowing engineers to learn without disrupting live operations.
• Asset interoperability twins (24%) use common data standards to share information smoothly and improve cross-platform data search.
• Maintenance twins (21%) find faults early, plan service better, and cut unplanned downtime.
• 3D visualisation twins (20%) clearly show complex systems.
• Product simulation twins (9%) test design performance before manufacturing.

Digital Twin Adoption Across Industries And Enterprises

• More than 75% of businesses have already adopted digital twin technology, and many are using it at least at a medium level of sophistication.
• About 70% of C-suite technology leaders at large enterprises are either evaluating or already investing in digital twins.
• By 2028, at least 59% of executives worldwide plan to adopt digital twins across their operations.
• A report shared via Business Wire states that over 94% of IoT platforms are expected to include some form of digital twin capability.
• More than 96% of vendors say that IIoT APIs and platform-level integration are essential for delivering digital twin capabilities across industrial sectors.
• While 42% of executives across industries recognise the benefits of digital twins, 59% expect to operationalise the technology by 2028.
• More than 57% of businesses have invested in digital twin technology to strengthen sustainability efforts.
• More than 40% of large companies globally are expected to adopt digital twins for revenue-focused projects by 2027.
• Among IoT-enabled organisations, about 75% have adopted digital twins or plan to do so.
• The Manufacturing IT/OT Trend Report 2025 notes that more than 40% of manufacturers are in the pilot phase, indicating a move toward an enterprise-wide rollout.

Operational Metrics

• According to McKinsey, in 2025, digital twins were linked with 20%-30% better capital and operational efficiency in public infrastructure programs.
• In 2026, 62% of organisations said they expect to move up by 1 technology maturity level (with 17% expecting gains of 2+ levels).
• Around 21% of organisations expect to remain at the same maturity level, while the remainder expect to improve.
• Science Direct report stated that in 2025, AI-enabled digital twins were associated with a 35% drop in unplanned downtime in energy-related predictive maintenance.
• An 8.5% increase in energy production and a 26.2% reduction in energy costs from AI + digital twin use cases, while energy savings of up to 30% after implementing a digital twin.
• Deployments achieved 98.3% accuracy for fault detection in energy applications.

Digital Twin ROI Statistics

• The McKinsey report further stated that interviews with senior R&D leaders indicate that digital twins can reduce total development time by up to 50%.
• System-level digital twins cut transportation and labor costs by 10% and improve reliability by 20%.
• Digital twins can boost revenue up to 10% through immersive, personalised product experiences.
• They can cut consumer electronics scrap waste by 20%, boosting sustainability.
• An automotive OEM used part-level digital twins, boosting contribution margins by 5%-10%.
• Also cut unplanned stoppages by up to 20% and improve maintenance planning.
• An optimisation engine in a digital twin cut emissions by 7% and improved on-time fulfilment by 5%.
• Deloitte reports 76% of manufacturers invest in digital tools to improve supply visibility.
• Early adopters report 20%-30% higher forecast accuracy and 50%-80% fewer delays and downtime incidents.
• Even mature procurement teams save 3%-6% by using digital twins for better decisions.
• Digital twins can cut building greenhouse gas emissions by up to 50% and operating costs by up to 35%, according to Sustainability Mag.
• Additionally, boost logistics revenue by up to 10% and quality by up to 25% via smarter planning.
• EY reports component-level digital twins helped an aviation firm detect 99.9% jet-engine part anomalies.

Digital Twin Use Cases

(Reference: databricks.com)

• Digital twins are most commonly used to improve product quality (34%), reduce manufacturing costs in USD (30%), reduce unplanned downtime (28%), increase throughput (25%), and ensure safe manufacturing (24%).
• Less common uses include testing new design ideas (16%), developing product enhancements (14%), enabling enterprise digital transformation (13%) and speeding new product information (13%), reducing planned downtime (11%), meeting regulatory challenges (10%), training for new manufacturing processes (8%) and managing production line design changes (8%), providing service to end customers (5%), and updating products in the field (1%).

High-Impact Urban Use Cases

• According to Toobler, digital twins test zoning, transit, and growth plans shaping mobility that cuts congestion 30%.
• Always-on monitoring spots bridge and tunnel risks early, reducing downtime 40%.
• City simulations predict energy demand, meeting net-zero goals with 15%-25% lower use.
• Flood, heat, and sea-level models help cities prepare and send real-time alerts during extreme events.
• Live network optimisation improves flow, lowers emissions, and supports multimodal travel.
• Sensor, camera, and drone data boost awareness, cutting response times by 50%.
• Predictive maintenance boosts the efficiency of public buildings and lowers operating costs by enabling timely maintenance.

Conclusion

Digital twins use live data to create virtual models of real systems, helping detect issues early, test changes safely, and improve performance. This reduces downtime, saves money, and improves quality. With IoT, cloud, and AI growing, digital twins will be easier to use in factories, healthcare, energy, and smart cities.

With good data, clear goals, and regular updates, digital twins help companies make faster decisions and run systems more safely.

FAQ