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ScienceDirect
Procedia CIRP 119 (2023) 638–643

33rd CIRP Design Conference

Use case for the Application of the Industrial Metaverse Approach for
Engineering Design Review
Fahmi Bellalouna*, David Puljiz
University of Applied Sciences Karlsruhe, Moltkestrasse 30, Karlsruhe, 76133, Germany

* Corresponding author. Tel.: +49-721-925-1862; fax: +49-721-925-1915. E-mail address: [email protected]

Abstract

The metaverse is an immersive virtual space that enables users to meet each other virtually as an avatar and to interact with the virtual environment
whatever their location. The metaverse approach is mainly based on the virtual reality (VR) technology enhanced with multiplayer capability.
VR enables, due to its high immersive and interactive capabilities, a realistic experience of complex and abstract technical systems which leads
to the support of the human cognitive abilities in observing their behavior. The advantages of VR have been recognized by the industry in the last
few years. As a result, numerous industrial companies worldwide have founded initiatives with research institutions and start-ups to investigate
the application of VR and the metaverse. This paper presents and discusses the implementation and the application of an industrial metaverse
approach based on VR for the design review of a pharmaceutical vial filling machine.
© 2023 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer review under the responsibility of the scientific committee of the 33rd CIRP Design Conference

Keywords: Industrial Metaverse; Virtual Reality; Avatar; Design Review.

1. Introduction between experts anywhere on earth. Immersion is also a key

aspect of the metaverse. Here specifically, Virtual Reality acts
Industry has gone through three major revolutions, the use as a key enabler due to its faithful representation of digital
of steam power and machines, mass production and finally the worlds in fully interactable 3D. Using the metaverse and VR,
use of automation and computers. It can be argued industry is this paper presents a novel metaverse application for the design
at the moment going through the fourth one, the use of cyber- review of a pharmaceutical vial filling machine. In the next
physical systems. Whether one uses the nomenclature of sections the fundamental concepts, such as the already
Industry 4.0 as in Europe or the Industrial Internet of Things mentioned metaverse, will be defined in-depth. Section 3 will
(IIoT) as common in the United States, the idea is the same – present the state of the art of the field and how this work relates
large scale networking of machines and facilities, and to it. Section 4 describes the use case. Section 5 presents the
ubiquitous accessibility to large contents of data. The used IT tools and technologies for the implementation of the
cornerstone of this approach is having a virtually exact copy of presented industrial VR metaverse application. In section 6 the
the real machine and facility in the digital world called a digital evaluation of the implemented VR metaverse is discussed.
twin. One interacts with the twin in the digital world the same Section 7 recaps the main results of this work and gives a brief
way as one would interact with the physical version. The outlook on further project activities.
industrial metaverse can be considered a unified network of
digital twins, yet it also represents a digital world where
discussions, prototyping, designing and training can take place

2212-8271 © 2023 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer review under the responsibility of the scientific committee of the 33rd CIRP Design Conference
10.1016/j.procir.2023.03.116
 Fahmi Bellalouna et al. / Procedia CIRP 119 (2023) 638–643 639

2. Fundamentals a digital copy of a physical object [1]. This object is usually a

device possessing sensors and/or actuators. One simple
The metaverse [12] is a fully integrated virtual world, where example would be flipping a virtual light switch in the
people can interact, work and play games. Though quite similar metaverse to turn on the light in the physical room. A more
to the internet, the metaverse is more than a collection of complex one may be a virtual representation of an industrial
webpages or apps, rather it is a truly integrated 3D virtual machine with real-time sensor readings, ability to interact
world. Until recently the metaverse was a mostly hypothetical remotely and even simulate and predict machine behavior
construct of many Sci-Fi books, most notable the Neuromancer based on past observations. Digital twins are perhaps the most
(which introduces the concept of cyberspace), Snow Crash important part of the industrial metaverse [11], a subset of the
(which introduced the word Metaverse) and Ready Player One metaverse focused on production, maintenance and
(with one of the most well-known descriptions of a Metaverse collaboration between experts in the field of industry. The user
– OASIS). Two small scale implementations of the concepts may physically be in Spain inspecting virtually a plant in
are worth mentioning for further clarity – the computer game Germany and calling in experts from the US who arrive in the
Minecraft and Second Life – a 3D virtual world where people virtual factory in a few minutes. Factories may be inspected,
could meet, chat and perform various activities. controlled and simulated in the virtual world. More than just
Though the metaverse can be accessed through any device, production and maintenance, the metaverse would allow rapid
the most prevalent form in literature and research is through prototyping and design review by allowing rapid modifications
Virtual Reality devices. Virtual Reality immerses the user in a and inspections in the virtual world significantly reducing the
full 3D virtual world where the user is free to move around and time between the requirement definitions and the finished
interact with digital objects as they would in the real world. product. Customers of a product or service can be present in the
Today the prevalent method of achieving this is through the use virtual world every step of the way, not only reviewing the
of headsets incorporating displays (also called HMDs: Head product but also getting better expectations of what is feasible
Mounted Displays), localization capabilities and trackable and what not, as well as learning from the inception how to
hand-held controllers. The movement of the headset and the operate the product itself. This concept is referred to as
controllers in the real world is precisely mimicked in the virtual customer onboarding.
world. Virtual Reality is a subset of Extended Reality (XR),
together with augmented reality, which blends digital and real- 3. Related works
world information. The VR enables a fully immersion in the
VR world and real-time interaction with the in the VR The use of VR in the industrial product design and design
environment included objects without restriction. With the help review has attract substantial attention. A review of product
of VR technology complex and large-scale systems (e.g. design and design review through the use of VR can be found
technics, nature, chemistry, anatomy, buildings) can be in [6]. Balzerkiewitz et al. [3] argue that VR greatly reduces the
presented adequately and tangibly even for non-experts and accumulated cost of product development, due in part to the
new interactive and intuitive engineering application can be ease and intuitiveness of design reviews through VR which can
realized. The improvement and expansion of the spatial happen more frequently with virtual than with physical
perception of complex technical products in the VR meetings. In [9] results of design review processes were
environment compared to desktop presentations has been compared between a non-immersive collaborative virtual
proven by several scientific studies. The use of VR reduces the environment (desktop CAD tool) and an immersive VR-based
cognitive effort required to imagine complex systems and one. It was found that in general more errors were found with
products, and therefore enables a more thorough analysis of a the non-immersive version, however the immersive solution
technical system [11]. VR helps the human sensory abilities performed better with larger designs. These findings contradict
that are required for the spatial perception of complex systems. the ones in [15], and the authors suggest that it should be tested
The participants in several scientific studies on the use of VR with more toolkits and that, perhaps, a hybrid approach with
in the product design and manufacturing reported that VR immersive and non-immersive collaborative environments
helped them to better understand the complexity of technical would yield the best results. Adwernat et al. discuss the
products and systems and that they have a more secure sense of implementation of an immersive design review software for
perception [5], [7], [9], [10]. These advantages of VR can drive cyber-physical systems in [2]. It was identified that the users
the approach of the Industry 4.0 and the digitization of the need a short training time to familiarize themselves with the
engineering processes. As consequence of this, recent years has software and process. The need for better native support for
seen VR applications, game environments explode in CAD files, which currently need prepossessing in regards to the
workplace training and industry [8]. level of detail, has also been mentioned. Bellalouna [4] also
An important aspect of such digital worlds is the Avatar – mentioned the need of better interaction between CAD files and
the digital representation of a human user in the virtual world. VR environments. It was also shown that VR can be efficiently
These avatars tend to mostly be 3D articulated humanoid used for requirement management and design review by
models but that is not always the case. The avatars interact with replacing costly physical mockups. Zenner et al. [16] propose
each other in the digital world, commanded by the user and an immersive VR-based system for exploration and
indeed representing the user itself. Another important virtual visualization of event-driven processes by non-experts. Such
object is a digital twin [14]. Although there is currently no systems are of great benefit for customer onboarding, but also
standardized definition of a digital twin, it is usually defined as for employee training. In [6] it was argued that VR not only has
640 Fahmi Bellalouna et al. / Procedia CIRP 119 (2023) 638–643

benefits in customer satisfaction through onboarding and  Multi-users functionality.

remote support, but also for customer retention and acquiring  Hybrid-access to the machine VR environment using a VR
new customers. HMD (Head mounted Display) and a PC desktop.
 Realistic interaction with the machine in the VR.
4. Use case: Industrial metaverse for design review of Based on those requirements a prototype for an industrial
pharmaceutical vial filling machine VR metaverse was implemented in cooperation between the
xR-Lab (eXtended Reality Lab) of the University of Applied
4.1. Motivation Sciences Karlsruhe and the company Syntegon. In the
following section the functions of the VR metaverse will be
This use case was carried out with Syntegon Technology presented.
GmbH, a German manufacturer for processing and packaging
technology in the pharmaceutical and food industries. 4.2. Industrial VR metaverse for design review of
Syntegon develops and produces highly specialized filling and pharmaceutical vial filling machine
closing machines of vials and infusion bottles in the medium
and high output range. The design and the manufacturing of The main objective of the industrial VR metaverse is the
such kind of machines are very customer specific as well as replacement of the elaborate PMU-based design-review
time and cost intensive. Every produced machine can be process using the 3D-CAD models of the filling machine. The
considered as a unique on the market. This requires very close 3D-CAD models should be transferred from the CAD
and comprehensive coordination and exchange between the application to the VR space to enable a complete virtual design-
customers and Syntegon, especially during the earlier product review. The developed VR metaverse comprises the following
lifecycle phases: product sales, product planning and product main functional modules:
design. Since the filling machine (Figure 1) is very large and
does not exist physically in the earlier product lifecycle phases,  3D-CAD data transformation from CAD application to VR
a tangible presentation based on conventional sales and design space
documents (e.g. catalogues, video, CAD data) of the whole The main challenge when developing a VR application for
machine and its components for the customers is hardly engineering is currently the transformation of the 3D-CAD data
possible. In order to cope with this challenge, Syntegon resorts from CAD applications into VR space. 3D-CAD models are
to special physical machine mock-up crafted in elaborate ways. very heavy and data intensive due to high geometrical and
These physical mock-ups (PMU) are used during the sales topological content (e.g. invisible interior surfaces of objects,
phase for the requirement engineering to discuss and collect the high number of polygons to map curves and tolerances). A
customer requirements, and during the design process for the smooth 3D graphic representation in the VR space requires at
design review. This demands a continuous update of the PMU least 90 FPS (Frame Per Second), which usually cannot be
according to the latest design level. Furthermore, the PMU- achieved with heavy 3D-CAD models. Based on native 3D-
based process requires an onsite personal attendance of the CAD models 30 – 40 FPS can normally be achieved, which is
costumer at Syntegon. In case of international costumers, this not sufficient for VR application and causes motion sickness
causes high travel expenses and travel times, and thus (so-called VR sickness). Therefore, the conversion of the CAD
additional project costs. If the customer cannot attend the data into VR-conform graphic data is needed. Since manual
meetings in person, the Syntegon engineers will be equipped data processing and conversion is very time-consuming, a data
with body cams to show the PMU via video conference transformation algorithm was implemented in this work that
systems. This special procedure is very intricate and, in most enables automatically a VR-conform graphic data preparation
cases, cannot lead to the expected result. based on native 3D-CAD models. The algorithm contains 7
data processing steps and was implemented using Python
within the graphic application PiXYZ Studio (Figure 2).

Fig. 1. Pharmaceutical vial filling machine [Syntegon].

The investigation of the capability and the potential of the

VR technology to replace the PMU-based design-review
process was addressed in this use case. Syntegon defined the Fig. 2. The 3D CAD data processing steps for the CAD-VR-Data
following requirements for the implementation of the transformation.
pharmaceutical vial filling machine in the VR metaverse:
 Loading of 3D CAD models of different machine types in  Multiplayer function
the design-review VR environment at runtime.
 Fahmi Bellalouna et al. / Procedia CIRP 119 (2023) 638–643 641

One of the main functions of a metaverse is the multiplayer demonstrate the interaction functions. After that, the user can
function that enables the participation of several users in the repeat the shown action accordingly.
same VR space in an immersive and interactive way
simultaneously. The multiplayer function also contains a voice  Learning VR space
and text chat that allows the communication between all After completing the tutorial, the user enters the learning VR
participants. The simultaneous participation can be done space. The learning space includes the “Wall of Syntegon”
independent of the user’s physical location enquiring only (Figure 4) that presents several data and information about
internet access. Thanks to these features, the design-review of Syntegon, its products, services and technologies. In addition,
the filling machine can be done remotely in the VR space under many walls are placed in the VR learning space, which can be
the attendance of different persons (e.g. sales engineers, design used as video player, PDF reader or white board to display
engineers, costumers) that are based in different world regions. further learning content for different Syntegon products and
This is very important for a global company such as Syntegon services. The learning VR space is also equipped with e-mail
that is presented in all regions of the world with more than 30 application that allows sending e-mails from the VR metaverse.
locations in 20 countries.

 Hybrid access function

The VR metaverse was implemented as a hybrid VR
application, which can be used as an immersive VR space and
as non-immersive desktop application simultaneously. That is,
the VR metaverse can be accessed via immersive VR devices
(e.g. HMD) and non-immersive VR devices (e.g. PC screen,
tablet PC, smartphone) at the same time. This enables a wide
use of the VR metaverse even for users without immersive
devices, e.g. customers from developing countries who lack the
required immersive VR equipment (e.g. HMD, VR computer). Fig. 4. “Wall of Syntegon” in the Learning VR space.

 Function for login and avatar creation  VR cleanroom

The VR metaverse includes an intro VR room for login. In The VR cleanroom is the VR metaverse area dedicated for
this room, the users can choose between multiplayer-mode and the design review of the filling machines (Figure 5). In this
single-player-mode and configure their own VR avatars room the 3D graphic models of the filling machines can be
(Figure 3). The VR avatars are useful to identify the different loaded in runtime. To interact with loaded machines in a
users in the VR space. For the user-specific avatar realistic way, several interaction functions have been
configuration, an avatar editor was implemented. With this implemented. The positioning function allows the machine to
editor the name of the avatar can be defined and several avatar be moved in the cartesian coordinate system: translation along
characteristics can be selected, e.g. sex, skin color, haircut, the x-, y and z-axis and rotation around the x-, y and z-axis. The
eyeglasses. In addition, within the intro room the language Measurement tool can be used to measure and check the
(German, English and French) can also be selected. distance between different objects in the VR cleanroom (e.g.
height, length, width of the machine and its parts). Notes can
be created and posted anywhere in the VR metaverse using the
Note function. This enables to note the discussed issues (e.g.
changes, new requirements, failures) arisen during the design
review accurately. Not least, the users have also the possibility
to interact with the different parts of the machine via grab,
(dis)assembly and teleport functions. In order to achieve an
accurate and reliable design review, the Collision between the
different parts of the machine should be detected and shown as
the parts are moved. This feature is realized using the collision
detection functions. This allows various processes and tasks to
Fig. 3. Avatar editor and terminal to select the mode Multiplayer / Single- be reviewed and evaluated virtually in realistic ways (e.g.
Player. (dis)assembly, (re)tooling, operating the machine, collision
 Metaverse tutorial check). The results of the design review can be saved and used
It can be assumed that most users have little or no experience at later time.
with the VR metaverse and its functions. Hence, an extensive
metaverse tutorial was implemented, which must be completed
by the new users before entering the workspace. The tutorial
area contains several stations, each focusing on a main VR
interaction function (e.g. teleport, object grab, object placement
and assembly). A tutorial video is shown at each station to
642 Fahmi Bellalouna et al. / Procedia CIRP 119 (2023) 638–643

visual and sound feedback as well as UI interactions. The XR

Interaction toolkit was used to implement all the basic
interaction function in the VR metaverse.

5.4. Photon Asset

For the network solution for multiplayer integration, the

assets of Exit Games were used. These offer a simple
implementation, many resources for learning the framework,
and detailed documentation. Photon PUN 2 was used for
Fig. 5. The cleanroom VR space with the filling machine. general synchronization between all users and VR room
management and Photon Voice 2 provides the voice chat.
5. Implementation
6. Evaluation
Several standard IT tools were used for the implementation
of the industrial VR metaverse, which are presented in the An evaluation workshop was held to obtain feedback from
following subsections. Syntegon engineers on the implemented Industrial Metaverse.
Five engineers with a long experience on design review process
5.1. PiXYZ Studio have attended the workshop. The participants received a short
introduction to the VR metaverse (duration: 5 min), then they
The CAD data processing was implemented on the basis of carried out a design review process within the VR space
the 3D data preparation and optimization tool PiXYZ Studio according to a defined scenario (duration: 30 min). After
from Unity Technologies (Figure 6). PiXYZ has a scripting completing the VR metaverse test, the participants provided
interface with the programing language Python, which was their feedback based on a 19-questions questionnaire on the
used in this work for the implementation of the algorithm for following topics:
transforming the 3D CAD data into VR capable graphic 3D
data.  VR Sickness: during the 30 min test of the VR metaverse,
the involved users did not experience motion sickness.
This is thanks to the powerful VR devices (HMD) and the
VR computer as well as the well-prepared 3D graphic
models. Still, the use of the HMD for a long period of time
can be very tedious (e.g. a design review with customers
can take several hours).
 3D graphic presentation: All the machine graphic details
required for the design review process can be accurately
viewed in the VR space.
 Interaction functions: Simple VR controllers have been
implemented to interact with the machine in the VR space.
Fig. 6. Algorithm for transforming 3D CAD data into VR capable graphic For simple tasks (e.g. grabbing parts) this might be
3D data using PiXYZ. sufficient. Though, for a better review and evaluation of
e.g. machine operation, (re)tooling, (dis)assembly accurate
5.2. Unity VR input / output devices e.g. VR gloves should be
implemented.
Unity real-time development platform and game engine  Avatar implementation: The use of the avatar facilitates
from Unity Technologies was used to develop the application. the communication between the different users in the VR
The platform provides a development environment to generate metaverse. The avatar enables the identification of the
rich and interactive real-time 3D experiences. Unity offers, users and its position in the VR space in real time.
among other things, a built-in physics engine that allows the However, the tracking of human body position and
simulation of 3D motion, mass, gravity and collisions. movement (e.g. for ergonomic evaluation of the machine)
cannot be done based on the implemented avatar character.
5.3. XR Interaction Toolkit This requires the implementation of sophisticated body
kinematics.
The XR Interaction Toolkit package is a high-level,  Hybrid access: The hybrid access to the VR space with
component-based, interaction system for creating VR and AR immersive (VR HMD) and non-immersive devices (e.g.
experiences. The core of this system is a set of base interactors PC, smart devices) is a very important feature of the
and interactable components, and an interaction manager that implemented VR metaverse. This allows the users without
ties these two types of components together. The XR VR infrastructure (e.g. VR HMD, VR computer) to access
Interaction Toolkit supports the basic interaction tasks e.g. the VR metaverse using common devices. However, it is
controller input and output, object select and grab, haptic, to be noted that the access with non-immersive devices
 Fahmi Bellalouna et al. / Procedia CIRP 119 (2023) 638–643 643

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