Podcasts · The Hardware Podcast with Fexingo: Chips, Devices, and Electronics Engineering Conversations

How Chips Are Using On-Chip Digital Twins for Real-Time Simulation

11 Jul 2026 · 11 min · S3 E105

In episode 105 of The Hardware Podcast, Lucas and Luna dive into the emerging use of on-chip digital twins — miniature virtual replicas of a chip's own circuits running in real time on the same silicon. They explore how companies like Siemens and Ansys are enabling this technology for adaptive power management, predictive failure detection, and dynamic performance tuning. The hosts discuss a specific case: a recent paper from imec demonstrating a 7-nanometer test chip that uses an on-chip digital twin to reduce power consumption by 18% under varying workloads. Lucas explains how the twin models thermal and electrical stress at the transistor level, while Luna questions the overhead cost and design complexity. The conversation covers the difference between traditional simulation and on-chip digital twins, the role of machine learning in creating compact models, and why this could change how chips handle reliability in automotive and data center applications. Tune in for a focused look at a technology that bridges simulation and real-time control.

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