Newly published research explores how Digital Twins and related innovative technologies could support safer products, and what needs to happen to support their adoption.
Rapid technological change is making products more connected and complex, supported by artificial intelligence, the Internet of Things and 3D printing. These developments could transform how products are designed, tested and monitored for safety. One less widely known but increasingly relevant technology is the Digital Twin.
A Digital Twin is a virtual representation of a physical object, product, service or system that is updated using real-time data. In practice, this means:
Data flows from the physical product to its digital representation (for example, through sensors)
- Insights flow back (for example, as recommendations or automated adjustments)
This two-way feedback loop supports product safety by monitoring real-world performance, learning from live data and informing improvements after products reach the market. Sensor data, such as shape, energy use, temperature or performance, can update the virtual version and improve predictions and decisions.
Although Digital Twins sound modern, the idea dates back to the 1960s, including NASA simulations for Apollo 13. They are now used in healthcare, automotive and construction to support patient care, performance monitoring, autonomous vehicle development and building design.
What did this study focus on?
OPSS commissioned a scoping study on digital innovation in product safety, focused on Digital Twins. It explored how the technology is developing, where it is used, and what it could mean for consumers, businesses and regulators.
This blog summarises the report’s key messages and highlights where collaboration and learning could support UK adoption. The research included a rapid evidence assessment, literature review, and interviews and workshops with stakeholders from industry, academia, government and conformity assessment bodies. It also considered why adoption varies by sector and what may limit wider use in consumer products.
Key takeaways
1) Digital Twins have the potential to protect consumers from harm
Digital Twins could improve safety through:
- Virtual testing during product development, including testing scenarios that may be hard or dangerous to recreate physically
- Earlier warning signals through real-time monitoring of performance and usage patterns
- Stronger traceability, described as a “golden thread” of information from the supply chain to the consumer. This could support counterfeit detection and more targeted recalls.
- Potential longer safe product lifespan through predictive maintenance and timely interventions
Digital Twins will not replace existing safety processes or physical testing, but over time they could provide useful evidence and support safety decisions.
2) Digital Twins are at an early stage of commercialisation in consumer products
As costs fall and technology improves, the use of Digital Twins is likely to grow in consumer goods, beginning with higher-value items, such as some white goods.
3) Barriers include standards, data sharing, skills and cyber security
Challenges that may slow adoption or limit impact:
- Limited shared understanding of what a “Digital Twin” is
- The need to improve the way different systems and datasets work together (‘interoperability’), and clearer frameworks for secure data sharing
- Capability gaps in data processing, modelling and assurance
- Concerns around cyber security
- IP and data-sharing concerns
4) Regulation and standards could support adoption, while allowing for innovation
Rushing standardisation could lock in unsuitable approaches. Flexible and proportional frameworks will need to adapt over time as technology evolved.
What are the implications for OPSS?
The report suggests that with appropriate standards and governance, virtual testing data could become a useful addition to OPSS’s regulatory framework.
The report mentions some areas OPSS may wish to explore further, including:
- Which safety metrics could reliably be supported by Digital Twin-enabled virtual testing, alongside physical testing
- What data is needed for assurance and market surveillance, while avoiding unnecessary burdens on businesses
- How secure data sharing and cyber-resilient approaches could be supported, in collaboration with wider government partners
- How OPSS capabilities, tools, and processes may need to adapt if new forms of digital evidence become more widespread
Call to action
Digital Twins and related innovations are developing quickly, and decisions made now will shape their role in product safety.
If you work on Digital Twins, virtual testing, product monitoring, data interoperability or assurance for connected products, we welcome your input to help build evidence on what works in practice and supports safe, trusted adoption.Read the full report: https://www.gov.uk/government/publications/digital-innovation-in-product-safety-a-scoping-study
This report was commissioned by the Office for Product Safety and Standards and prepared by RSM Consulting LLP.