A methodology for estimating the cost of a digital twin

This paper proposes a methodology for estimating the cost of developing digital twins (DTs) in manufacturing processes. It formulates a cost model that identifies main cost elements and presents the estimation process for establishing an acceptable cost reference based on a given set of physical information entities as DT inputs. To achieve this, six core data activities are derived from the ISO 23247 DT reference framework and the Digital Twin Data concept to characterize the functioning of DTs from a data perspective. These activities are data gathering, data interaction, data storage, data processing, data servitization, and data maintenance. The activity-based costing (ABC) method is applied to allocate six resources in the development of DTs (personnel, machine, equipment, material, facility, and service) to these data-intensive activities. The resultant cost structure comprises 40 cost activities, along with associated quantitative metrics. This work presents a case study on developing a DT for estimating the dimensional accuracy in the MEX process, where thermal and acceleration measurements are considered. For the information set with extruder and build plate temperatures as well as X- and Y-axis acceleration, developing a DT is estimated to cost between £4780 (for one temperature signal) and £39,285 (for two temperature signals and two acceleration signals) for two years of service and one year of data archiving. In addition, the cost distribution across four categories (IT infrastructure, resource, data activity, and investment) are analysed. The derived insights can support cost-related analysis, physical information entity selection, budget control, and standard open databases for DT costs.