ABB Robotics has announced a significant step toward the future of industrial automation by integrating NVIDIA Omniverse libraries into its RobotStudio software platform. Through this development, the company enables manufacturers and industrial organizations to implement physical AI within real-world robotics applications. As industries increasingly adopt advanced automation technologies, this integration aims to bridge the long-standing gap between virtual simulations and real-world deployment.

For decades, manufacturers have relied on simulations to design and optimize robotic processes. However, differences between simulated environments and real factory conditions often limited the accuracy of these models. With the integration of NVIDIA’s advanced simulation technologies, ABB Robotics now addresses this challenge directly, allowing developers to create highly realistic simulations that closely mirror real-world performance.

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“Thanks to NVIDIA’s simulation technologies, we have closed the so-called sim-to-real gap. This paves the way for making physical AI a reality in industry worldwide,” says Marc Segura, President of ABB Robotics. “For more than 50 years, ABB Robotics has been driving intelligent industrial automation. We pioneered the development of the first generation of all-electric industrial robots, introduced simulations with digital twins using RobotStudio, and launched a new type of autonomous and versatile mobile robot. By collaborating with NVIDIA, we are now making the widespread use of physical AI in industry possible.”

Through this collaboration, ABB combines the programming and simulation capabilities of RobotStudio with the physically accurate simulation environment powered by NVIDIA Omniverse libraries. As a result, developers can model robots as digital twins, enabling them to generate synthetic data that trains physical AI models. Consequently, companies across industries regardless of size can deploy AI-powered robotics to automate complex industrial workflows more efficiently.

Furthermore, the system continuously refines simulations and AI foundation models through RobotStudio HyperReality. Real-world operational feedback constantly improves these models, allowing organizations to train ABB robots anywhere in the world while maintaining the reliability and precision required in industrial settings.

“The industrial sector needs physically accurate simulations to bridge the gap between virtual training and the real-world deployment of AI-driven robotics,” says Deepu Talla, Vice President of Robotics and Edge AI at NVIDIA. “The integration of NVIDIA Omniverse libraries into RobotStudio combines our advanced simulation and computing power with ABB Robotics’ unique virtual control technology. This accelerates the process by which manufacturers of all sizes bring complex products to market.”

Bridging the Sim-to-Real Gap

Historically, manufacturers struggled with the “sim-to-real” gap the difference between theoretical simulations and actual factory operations. Variations in lighting conditions, materials, and environmental factors often reduced the reliability of virtual testing.

Now, ABB Robotics, together with NVIDIA, has significantly narrowed this gap. Using highly detailed simulations and synthetic data generated within NVIDIA Omniverse, intelligent robots can achieve up to a 99 percent match between simulated models and real-world performance.

A key factor in this advancement is ABB’s Virtual Controller, which replicates the exact software used to operate real robots. By combining this capability with Absolute Accuracy technology which reduces positioning inaccuracies from 8–15 millimeters to just 0.5 millimeters ABB delivers an unprecedented level of precision in digital simulations. As a result, manufacturers can confidently use virtual environments to plan complex industrial operations.

Accelerating Manufacturing Efficiency

With these innovations, manufacturers can now design, test, and optimize entire production lines virtually before implementing them on the factory floor. This shift significantly improves operational efficiency. According to ABB, companies can reduce setup and commissioning times by up to 80 percent. Additionally, eliminating the need for physical prototypes can lower costs by approximately 40 percent.

Equally important, the technology accelerates product development cycles. In industries such as consumer electronics, where speed and precision are critical, manufacturers can potentially cut time to market in half.

At the same time, ABB is exploring the integration of NVIDIA’s Jetson edge computing platform into its OmniCore controller. This initiative aims to enable real-time AI capabilities directly within robots across ABB’s entire portfolio.

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Early Industry Applications

Several organizations have already begun testing the technology ahead of its broader release. The official launch of RobotStudio HyperReality is expected in the second half of 2026, making it available to ABB’s global base of more than 60,000 RobotStudio users.

One early adopter is Foxconn, the world’s largest contract electronics manufacturer. The company is piloting a use case in consumer electronics assembly, where automation can be particularly challenging due to the complexity of small components and multiple product variants.

“In consumer electronics manufacturing, precision is everything. Until now, this level of accuracy and attention to detail was simply unattainable in simulations and digital twins,” explains Dr. Zhe Shi, Chief Digital Officer of Foxconn. “We see enormous potential in the collaboration between ABB Robotics and NVIDIA. Thanks to advanced AI inference, we can parallelize engineering processes, ramp up production faster, and significantly accelerate our overall product development.”

Using RobotStudio HyperReality, Foxconn trains assembly robots in virtual environments using synthetic data. Consequently, engineers can perfect production scenarios before deploying them on actual production lines with nearly identical accuracy. This process reduces debugging time, lowers engineering costs, and speeds up product launches.

Expanding Access to Smaller Manufacturers

Meanwhile, WORKR, a California-based robotics company specializing in industrial automation solutions, is bringing this technology to small and medium-sized enterprises in the United States. At NVIDIA GTC 2026, scheduled for March 16–19 in San Jose, WORKR will demonstrate AI-powered robotic systems trained entirely using synthetic data within NVIDIA Omniverse.

By combining ABB’s industrial-grade robotics with its proprietary WorkrCore AI platform, WORKR has developed robots that require no programming expertise. These systems can learn new tasks within minutes and can be operated by employees without specialized robotics knowledge.

“This collaboration is about making industrial AI practical today,” explains Ken Macken, CEO and founder of WORKR. “Together with ABB Robotics and NVIDIA, we are proving that advanced automation works for manufacturers of all sizes.”

Overall, the integration of NVIDIA Omniverse into ABB’s RobotStudio platform represents a major milestone for the industrial automation sector. By enabling accurate simulations, faster deployment, and AI-driven robotics, the collaboration promises to reshape how manufacturers design and operate modern production environments.

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