As automation engineering continues to evolve, organizations are moving away from traditional hardware-centric approaches toward more flexible, scalable, and intelligent systems. One of the most significant trends shaping the industry in 2026 is Software-Defined Automation (SDA).
By separating software from physical hardware and leveraging advanced simulation technologies, SDA is helping businesses increase agility, reduce costs, and accelerate innovation. Two key components driving this transformation are Virtual PLCs and Digital Twins.
Fixykor decided to dive into peculiarities of both approaches. Take a closer look at SDA key components we are going to observe.
Virtual PLCs: Redefining Industrial Control Systems
For decades, industrial automation relied heavily on dedicated hardware-based Programmable Logic Controllers (PLCs) to control manufacturing processes and equipment. While effective, these systems often require significant investments in hardware upgrades, maintenance, and deployment.
Today, automation engineers are increasingly adopting Virtual PLCs, which run as software applications on virtual machines, servers, or containerized environments.
Benefits of Virtual PLCs
- Greater flexibility and scalability
- Faster deployment of updates and new features
- Reduced hardware dependency
- Lower infrastructure and maintenance costs
- Simplified system management
- Improved integration with cloud and edge computing platforms
By decoupling software from hardware, organizations can modernize their automation infrastructure without replacing entire control systems. This approach enables faster innovation and supports the growing demand for agile manufacturing environments.
Digital Twins: Optimizing Operations Before Implementation
A digital twin is a virtual representation of a physical asset, process, or production environment. Using real-time data and advanced simulation technologies, engineers can model, test, and optimize operations in a virtual space before making changes in the real world.
In 2026, simulation-based engineering and the Industrial Metaverse are becoming mainstream tools for manufacturers and industrial organizations.
Benefits of Digital Twins
- Virtual testing without disrupting operations
- Faster identification of process improvements
- Reduced implementation risks
- Improved production efficiency
- Enhanced predictive maintenance capabilities
- Better decision-making through real-time insights
Engineers can simulate production line modifications, evaluate equipment performance, and identify potential bottlenecks before investing time and resources into physical deployment. This significantly reduces costs while improving operational outcomes.
To Sum Up: Why Software-Defined Automation Matters
As industries face increasing pressure to improve productivity, adapt to changing market demands, and support digital transformation initiatives, Software-Defined Automation provides a powerful solution.
Virtual PLCs deliver the flexibility needed to scale and modernize automation systems, while Digital Twins enable data-driven optimization and risk-free experimentation. Together, these technologies are helping organizations build smarter, more resilient, and future-ready operations.