Festo Develops Digital Twins for Physical AI Using NVIDIA Technologies
When a machine combines different functions, engineers must understand how these functions interact before the system is installed. Virtual models can help evaluate concepts, optimize machine processes, and resolve integration issues as early as the development phase. Festo has already implemented NVIDIA Isaac Sim, an open simulation framework, and synthetic data for robotic perception and automation capabilities. This experience, combined with the existing capability to export USD data, serves as the starting point for expanding models to include motion behavior and application-relevant properties, thereby enabling the reliable evaluation of components’ real-world behavior in simulations.
“The collaboration between NVIDIA and Festo is a milestone for the future of industrial automation,” says Prof. Dr. Tomas Smetana, Chief Technology Officer (CTO) at Festo. “By combining NVIDIA Omniverse libraries with Festo’s decades of automation expertise, we are creating a learning virtual environment for the autonomous production of the future.”
Festo’s Quality Standards for Digital Product Models
“Our digital models must be just as trustworthy as our hardware,” says Jan R. Seyler, Head of Physical AI and Digital Thread at Festo. “Our goal is to provide product models that meet Festo’s high quality standards and enable the development and validation of automation solutions that are as close to reality as possible.”
To systematically evaluate model quality in the future, Festo plans to compare measurements from its own laboratories with simulation results in NVIDIA Isaac Sim. This open simulation framework, based on NVIDIA Omniverse libraries, enables evaluation within complete automation scenarios. Under defined operating conditions, simulated movements and dynamic behavior will be compared with corresponding measurements taken on real components, and the models will be specifically improved.
Festo and ABB Robotics are collaborating with NVIDIA on a virtual handling application
A concrete step in this development is the collaboration with ABB Robotics and NVIDIA. In a joint handling application, the partners are integrating digital twins of a three-axis Festo handling system with ABB RobotStudio®. This is intended to help machine builders clarify processes and integration issues before physical setup, accelerate commissioning, and shorten time to market. The RobotStudio® HyperReality extension connects RobotStudio with NVIDIA Omniverse libraries for photorealistic, physics-based simulations. The ABB Virtual Controller makes it possible to virtually test robot programs using the same control software as on real ABB robots.
“Together with our partner network, ABB Robotics is developing more autonomous and versatile robotic solutions that can perform more tasks in more locations faster, safer, and more intelligently,” says Boris Fiedler, Head of Operations and Portfolio, Software and Digital, ABB Robotics. “The collaboration with Festo and NVIDIA will advance engineering and virtual commissioning for machine builders and help drive the widespread adoption of industrial-grade Physical AI across companies.”
For Festo, the collaboration represents a concrete step forward in developing a reliable digital foundation for Physical AI. In the long term, the company aims to narrow the gap between simulation and reality to the point where automation solutions developed virtually can be transferred to real machines with as little adaptation effort as possible.
Festo is a global player and an independent family-owned company with headquarters in Esslingen am Neckar, Germany. Festo has set standards in industrial automation technology and technical education ever since its establishment, thereby making a contribution to sustainable development of the environment, the economy and society. The company supplies pneumatic and electrical automation technology to 300,000 customers of factory and process automation in over 35 industries. Digitalization, AI and the LifeTech sector with medical technology and laboratory automation are becoming increasingly important. The products and services are available in 176 countries. With about 20,600 employees in over 250 branch offices in around 60 countries worldwide, Festo achieved a turnover of around €3.33 billion in 2025. More than 8% of this turnover is invested in research and development. In this learning company, 1.5 % of turnover is invested in basic and further training. Festo Didactic SE is a leading provider of technical education and training and offers its customers worldwide comprehensive digital and physical learning solutions in the industrial environment.
