The manufacturing sector is undergoing rapid transformation, with immersive technology like virtual reality (VR) playing a pivotal role.

It’s easy to see why; employees have to navigate large, expensive equipment and complex logistics, with accidents that can have significant, not to mention expensive, consequences. Immersive technology provides a way to simulate production processes without the labour and risks involved. In doing so, it holds the potential to streamline every stage of production, from product development and prototyping, employee training to the optimisation of production lines. Here are three ways VR is adding value to businesses:

Optimising design and collaboration

Combining 3D digital twin assets with VR technology offers more powerful design capabilities than traditional methods. Through true 1:1 scale virtual models, organisations can visualise and iterate design on a 1:1 scale in real-time regardless of location, eliminating the need for costly physical mock-ups. This rapid iteration allows 3D models to be instantly tested within a digital twin environment, enabling a larger team to review and provide feedback.

Forward-thinking organisations are already utilising this technology and seeing the benefits. In Australia, Ford Motor Company has embraced VR technology to enhance its vehicle design and manufacturing processes. By using VR headsets and immersive 3D modeling software, Ford’s engineers visualise and iterate on vehicle designs at a 1:1 scale in real-time. This capability allows them to bypass the traditional method of creating physical prototypes, saving significant time and financial costs.

Train manufacturer, Stadler, has also used VR for rapid iteration of the new Metro trains in the North East of England. With over 40 trains being delivered to run on the network for the next few decades to ensure the heart of the transport network can keep people connected, Stadler designed mock-ups in VR for Metro drivers to test. Over 155 drivers were able to test it in just nine weeks. This provided designers with immediate valuable feedback to be which was then implemented and iterated.

Enhancing planning and maintenance

Beyond design and visualisation, organisations have the power to enhance factory planning and maintenance with VR. These can be conducted in a 3D digital twin of any space, giving engineers a safe virtual environment to gain a clear understanding of changes and iterate at an earlier stage, all without disrupting day-to-day operations.

VR allows teams to simulate both small and large-scale environments without the need for physical prototypes. Able to visualise and reaarrange virtual replicas of machinery quickly and efficiently, teams  are able to explore and assess designs as if they were in the actual production environment, providing valuable insights into workflow and ergonomics.

Testing in a virtual space helps identify potential issues and refine processes early on, reducing the risk of costly changes later. This approach also supports remote collaboration, as teams can interact with virtual models from different locations, facilitating better communication and decision-making.

A tool for training

In industries where effective training is critical, the costs can be high. This is particularly true in the manufacturing sector, where the physical equipment and machinery used in training sessions often require costly setups, maintenance, and downtime. Training workers on real machines also poses safety risks, which can lead to damage or accidents, while creating life-sized mockups for training can consume significant resources, from materials to personnel.

VR technology offers a solution by offering safe, controlled environments where workers can safely train without the need for expensive equipment. In an industry where preparedness is key, VR training provides a space for repetitive practice, allowing workers to learn from mistakes without facing real-world consequences.

A standout example of this is Transport for NSW’s initiative for 3,000 train drivers and guards. The program enhances emergency preparedness by simulating various onboard scenarios within Waratah trains. Trainees practice vital procedures, such as deploying emergency ramps and using fire extinguishers, all within a safe virtual environment. By replacing traditional video-based training, this innovative approach demonstrates Transport for NSW’s dedication to improving both safety and efficiency in the transport network, by utilising cutting-edge technology.

Transforming the manufacturing industry through technology

As virtual reality continues to redefine manufacturing, it’s clear the technology offers more than just novel solutions—it presents a transformative shift. By optimising design processes, enhancing factory planning, and revolutionising training, VR allows manufacturers to improve efficiency and safety while reducing costs. And as the technology develops and becomes more ingrained in industry practices, its potential to streamline production and prepare teams for complex challenges will only grow. The future of manufacturing is immersive.

Thomas Dexmier, ANZ Country Manager at extended reality pioneer, HTC VIVE

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