Shipbuilding is undergoing a transformation driven by digitalization and the incorporation of advanced technologies such as digital twins.

This innovative tool makes it possible to simulate, optimize and monitor in real time every aspect of a vessel, from design to operation.

In this context, digital twins in the shipping industry are positioning themselves as one of the keys to improving the efficiency, safety and sustainability of maritime transport.

This article explores in depth how digital twins applied to shipbuilding are revolutionizing the industry, what benefits they bring to shipyards, shipowners and logistics operators, and what challenges their implementation poses.

1. What are digital twins?

A digital twin is a dynamic virtual representation of a physical object. In the case of shipbuilding, it is a 3D model connected to sensors that reproduce in real time the behavior of the ship:

• Structural and mechanical conditions
• Energy consumption and performance
• Condition of hull, engines, propellers and auxiliary systems
• Interaction with the marine and meteorological environment

By collecting data through the Internet of Things (IoT) and analyzing it through artificial intelligence, the digital twin enables informed decisions during all stages of the ship’s lifecycle.

2. Applications of digital twins in shipbuilding.

a) Predictive design and simulation

Prior to the physical construction of the vessel, engineers can:

• Validating different structural and propulsion designs
• Simulate extreme sailing or overload conditions
• Evaluate hydrodynamic resistance and behavior at sea.

This reduces errors, saves costs and improves the quality of the final design.

b) Optimization of construction processes

During shipyard manufacturing, the digital twin allows:

• Coordinating multidisciplinary teams in real time
• Anticipate planning and material variances
• Simulate the assembly of complex modules

Shipyards that integrate this technology achieve greater control over deadlines, resources and quality of execution.

c) Operation and predictive maintenance

Once in service, the digital twin remains active. Its use extends to:

• Real-time monitoring of the vessel’s status
• Early detection of failures through predictive algorithms
• Optimization of fuel consumption and navigation routes
• Improved operational safety in the face of changing conditions

In addition, it allows maintenance to be scheduled only when necessary, reducing downtime and costs.

3. Key benefits of digital twins in the shipbuilding industry

Operational efficiency

Digital twins enable up to 20% reduction in vessel operating costs through continuous performance optimization.

Sustainability and emissions reduction

By monitoring and adjusting consumption in real time, it facilitates compliance with international regulations such as IMO 2023 or the European Green Pact targets for decarbonization of shipping.

Improved maritime safety

Simulations based on digital twins make it possible to virtually test risk scenarios, train crews and activate protocols before critical situations.

Data-driven decision making

Whether on land or on board, operators have an analytical tool to support strategic decisions in design, logistics or maintenance.

4. Real cases of use in shipbuilding

Navantia and its Shipyard 4.0 program

The Spanish public company Navantia has incorporated the use of digital twins within its digital transformation strategy “Shipyard 4.0”, applying them in the construction of submarines and frigates with great results in quality control, efficiency and data traceability.

Rolls-Royce and its vision for autonomous ships

Rolls-Royce Marine has developed a digital twin model that integrates sensors and autonomous navigation for future unmanned ships, reducing human error and increasing routing efficiency.

Carnival Corporation

This cruise line uses digital twins to monitor its fleet and reduce energy consumption, as well as improve thermal comfort on board and ensure more sustainable operations.

5. Challenges for its implementation

Despite its advantages, the implementation of digital twins in shipbuilding presents challenges:

• High initial investment in sensors, software and training
• Need for common interoperability standards
• Management of large volumes of data (big data)
• Requires an advanced digital culture in the shipyard and among crew members

However, more and more companies in the sector are betting on its progressive implementation as a strategic asset for the future.

6. The future of digital twins in the maritime industry

The evolution of this technology points towards integration with:

• Artificial intelligence and machine learning for more accurate predictive analytics
• Augmented reality for on-board repair or inspection assistance
• Blockchain to ensure traceability of events and decisions
• Integration with logistics and port management systems

In addition, digital twins will be key in the development of sustainable, efficient and autonomous vessels.

Conclusions

Digital twins in shipbuilding are no longer a promise of the future, but a present reality that is transforming the design, manufacture, operation and maintenance of ships. They bring competitive advantages in efficiency, sustainability and safety, essential elements for an industry that seeks to adapt to new technological and environmental demands.

At Interseas Naval Service, we support technological innovation in the maritime sector. We help our customers to implement advanced solutions that optimize their logistics, operations and sustainability.