How Hardware Startups Are Using Digital Twins to Slash Iteration Costs

In this episode of Hardware Startups with Fexingo, Lucas and Luna explore how digital twins are transforming hardware development. Using the example of a drone startup that saved 70% on prototyping costs by simulating flight dynamics before building physical models, they discuss the software tools driving this shift—from Ansys Twin Builder to open-source options like OpenModelica. Lucas breaks down the math: each physical prototype can cost $5,000 to $20,000, while a digital twin iteration is essentially free after initial setup. They also cover how companies like Tesla and Siemens use digital twins for predictive maintenance, and why early-stage startups should adopt them before their first manufacturing run. The hosts tie it back to the hardware startup dilemma: building trust with investors and customers when you can't show a physical product yet. A natural donation segment emerges from the conversation about access to expensive simulation software, acknowledging that listener support keeps the show ad-free and accessible. #HardwareStartups #DigitalTwins #Prototyping #IterationCosts #Ansys #OpenModelica #Tesla #Siemens #Simulation #DroneTech #ProductDevelopment #Manufacturing #PredictiveMaintenance #BusinessAndTechnology #FexingoBusiness #BusinessPodcast #HardwareEngineering #StartupStrategy Keep every episode free: buymeacoffee.com/fexingo