Revolutionizing Factory-Scale Automation Testing with High-Fidelity Digital Twins

MILWAUKEE—(BUSINESS WIRE)—Rockwell Automation (NYSE:ROK), the global leader in industrial automation and digital transformation, is set to debut its groundbreaking Emulate3D® Factory Test™ at NVIDIA GTC 2025. This marks the first public demonstration of the innovative solution, designed to revolutionize Factory Acceptance Testing (FAT) by enabling manufacturers to conduct full-scale virtual controls testing before deployment. By integrating seamlessly with NVIDIA Omniverse™ APIs and OpenUSD, Factory Test introduces a new era of high-fidelity simulation and real-time collaboration in industrial automation.

Transforming Industrial Automation with Scalable Digital Twins

“As manufacturing complexity increases, the need for scalable, high-fidelity digital twins becomes more critical than ever,” said Matheus Bulho, Senior Vice President of Software and Control at Rockwell Automation. “With the launch of Emulate3D Factory Test, we’re providing a solution that allows engineering teams to test, iterate, and validate automation systems at factory scale. Leveraging NVIDIA Omniverse, we deliver unprecedented visualization and collaboration capabilities.”

As an automation engineer, I see this as a significant step toward reducing commissioning times and improving system reliability. Traditional simulation tools often struggle to accurately model factory environments due to their scale and complexity. However, Factory Test addresses these challenges by enabling teams to create, verify, and integrate models for mechanical, electrical, controls, process, robotics, and device behavior into a unified digital twin.

Key Capabilities of Emulate3D Factory Test

At launch, Factory Test will introduce several advanced features designed to enhance automation testing:

• Multi-model orchestration – Synchronizing multiple system models for factory-scale testing.

• Modern DevOps workflows – Enabling seamless version control, real-time tracking of changes, and streamlined deployment across teams.

• Test Runner – Automating and repeating tests at scale for consistent validation.

• Fault Framework – Simulating fault conditions to evaluate system resilience.

• Advanced full-factory visualization – Powered by NVIDIA Omniverse APIs, initially available via private preview.

Industry Implications: The Future of Digital Twins in Manufacturing

According to Brian Harrison, Senior Director of Omniverse Digital Twins at NVIDIA, “NVIDIA Omniverse and OpenUSD are redefining how industries use AI-driven simulation to optimize design and operations. With Emulate3D Factory Test, Rockwell Automation is integrating Omniverse technologies to bring next-generation digital twins to the industrial sector, helping teams simulate, validate, and optimize complex manufacturing systems at an unprecedented scale.”

From my perspective, the impact of this innovation extends beyond efficiency gains. By providing a virtual testing environment, manufacturers can:

• Reduce commissioning times, minimizing plant downtime.

• Identify and resolve automation issues early, before costly deployment failures.

• Improve cross-disciplinary collaboration by enabling engineers, operators, and managers to work with real-time synchronized models.

Live Demonstration at NVIDIA GTC 2025

The debut of Factory Test coincides with NVIDIA GTC 2025, held March 17–21 in San Jose, California. As part of the event, Rockwell Automation will present a session titled “Exploring Factory-Scale Digital Twin Simulation with Rockwell Automation” on March 20 at 11 a.m. PDT. This session will highlight how AI-driven simulation and digital twin technology are transforming industrial automation.

A Step Toward Autonomous Operations

This announcement follows Rockwell’s November 2024 collaboration with NVIDIA, aimed at integrating AI and physics-based simulation into industrial automation. Emulate3D Factory Test represents a major milestone in the push toward intelligent, autonomous operations.

For manufacturers looking to stay ahead in Industry 4.0, this technology is a game changer. The ability to simulate entire factories, conduct real-time stress tests, and optimize workflows before deployment will set new standards for efficiency and reliability in industrial automation.

[Click here to learn more about Emulate3D Factory Test.]

About Rockwell Automation

Rockwell Automation, Inc. (NYSE: ROK) is a global leader in industrial automation and digital transformation. By connecting human ingenuity with technology, Rockwell is committed to expanding what is possible in industrial productivity and sustainability. Headquartered in Milwaukee, Wisconsin, Rockwell employs approximately 27,000 professionals serving customers in over 100 countries.

To learn more, visit www.rockwellautomation.com.

Media Contact:
Chaya Jacobs
Director, Media & Social
Rockwell Automation
414-305-2784