What costs are involved when investing in a virtual trainer within a technical training program?

Q: What costs are involved when investing in a virtual trainer within a technical training program?

Before transitioning to shop-floor equipment, students often participate in controlled, supervised scenarios using actual machines. This hands-on phase bridges the gap between simulation and reality, reinforcing skills in a low-risk environment while also building their confidence. “The investment required for schools or manufacturers to acquire and implement a Machine Trainer unit includes several key components. First, there are costs associated with hardware and software, such as the Hexagon Machine Trainer system and licensing fees for simulation software, which also covers periodic updates,” Allen says. There are also implementation and training costs to consider, including expenses for installation and setup services, as well as initial training for instructors. It's also important to explore whether any programs or partnerships are available to make these investments more accessible.

Published 08/06/2025

Using a Simulator to Support Upskilling and Empowering Workers

A virtual machine tool trainer powered by digital twin technology helps bridge the labor gap, starting with school programs.

Christina Fuges

Editorial Director, MoldMaking Technology

Schools

Problem: Lack of skilled labor; lengthy and costly training

Solution: HxGN Machine Trainer simulator

Results: Students trained through practical experience without risking equipment damage, wasting materials or using production resources.

The Machine Trainer simulator uses digital twins to assist manufacturers in training machinists and metrology specialists on essential shopfloor equipment. “By combining hardware that realistically replicates machines with manufacturing simulations and operator software tools, it enables trainees to acquire practical experience without the risk of damaging costly equipment, wasting materials or using up valuable production resources,” says Dick Allen, Hexagon Manufacturing Intelligence director of Mold & Die.

The Setup

The simulator is designed to be as realistic as possible, featuring hardware that closely resembles the appearance and functionality of an actual machine. It is equipped with a 43-inch screen that displays accurate simulations of various machines and cutting tools. A light tower, physical CNC handwheel and coordinate measuring machines (CMM) joystick enhance the experience, enabling trainees to respond to issues and control machine movements just as they would in a real workshop environment. It also provides a variety of digital twins for CMMs, offering practical experience for users.

Each training unit can be equipped with up to two CNC controllers, including options from Fanuc, Heidenhain and Siemens, all on a single training console. The machine trainer uses the latest version of Hexagon’s NCSIMUL CNC simulation software to effectively simulate three-axis, five-axis and mill-turn machine tools. It also employs I++ Simulator software to simulate comprehensive metrology processes.

“Versatility is offered via a digital twin that can be created for a specific machine brand, type and configuration. Once trained, workers can easily transition to real machines.”

“Staff training to be machine tool operators, machinists and ultimately CNC programmers can use any of the two controllers to learn their respective conversational programming languages,” Allen says. Student exercises also include instruction sheets that mimic typical manufacturing workflows and job specifications, detail the virtual cutting tools to be assigned to jobs and outline the CNC program to be loaded onto the training unit.

In addition to troubleshooting and learning to switch between manual and automatic run modes as needed, students will learn how to set machine tool origins, define tool parameters and determine cutting tool compensation.

“Versatility is offered via a digital twin that can be created for a specific machine brand within NCSIMUL, type and configuration. Once trained, workers can easily transition to real machines,” Allen says.

Customizing a digital twin to match specific equipment typically depends on the software and the intended use case. “In our implementation, this process is centered around NCSIMUL, which is specifically designed for programming and simulation purposes. The customization involves configuring the software to align with the machines and controls available at the school or company. This process is managed by the NCSIMUL team and delivered as a complete solution, ensuring it matches the organization’s exact equipment,” Allen says.

For educational setups using the Machine Trainer, the focus is on teaching machinists how to operate physical control panels. These trainers use generic machine versions to emphasize control panel learning rather than detailed equipment-specific programming.

Students transition from simulation to reality through supervised, hands-on training with actual machines, building confidence.

Transition and Metrics

Students typically start by mastering key concepts and workflows on the Machine Trainer. This involves developing a comprehensive understanding of machine operations, programming, troubleshooting and process optimization in a virtual environment which simulates real-world conditions.

“Readiness is typically measured using several key metrics. First, performance benchmarks involve tracking task accuracy, efficiency and adherence to standard operating procedures during simulations. Operational timelines also monitor the time taken to complete assigned simulations, allowing comparisons to industry standards. Error analysis is also crucial; it involves reviewing the frequency and nature of errors to identify gaps in understanding or application,” Allen says.

To support this process, students receive ongoing feedback from instructors or training platforms, highlighting their strengths and areas needing improvement. Certificates or credentials may be issued to validate their competency levels, providing a concrete indication of their readiness for shopfloor operations.

Investment Requirements

Before transitioning to shopfloor equipment, students often participate in controlled, supervised scenarios using actual machines. This hands-on phase bridges the gap between simulation and reality, reinforcing skills in a low-risk environment while also building their confidence.

“The investment required for schools or manufacturers to acquire and implement a Machine Trainer unit includes several key components. First, there are costs associated with hardware and software, such as the Hexagon Machine Trainer system and licensing fees for simulation software, which also covers periodic updates,” Allen says.

There are also implementation and training costs to consider, including expenses for installation and setup services, as well as initial training for instructors. It’s also important to explore whether any programs or partnerships are available to make these investments more accessible.

Beyond Machining

There is interest in expanding the Machine Trainer’s capabilities beyond training machinists and CNC operators to include other manufacturing roles, such as mold designers and automation specialists. The Machine Trainer will be an essential tool for simulating machining tool paths with a high degree of precision, enabling users to visualize and analyze the machining process in detail, ensuring optimal tool performance and efficient pathing.

“A key feature of the trainer is its ability to evaluate fine surface finishes,

The simulator offers a highly realistic experience with hardware which mirrors the look and functionality of a real machine.

which are critical for the quality and functionality of machined molds. By incorporating this simulation into the workflow, users can identify and address potential issues before actual production begins, ensuring superior mold integrity and reducing costly rework,” Allen says. This advanced simulation capability provides both practical and strategic advantages, guaranteeing high-quality outcomes for complex machining projects.

Hexagon offers various types of support and training for instructors and trainees to ensure the effective use of the Machine Trainer in both educational and industrial environments. “The instructor training programs are designed to equip educators with the necessary skills and knowledge to seamlessly integrate the Machine Trainer into their curriculum, covering software functionalities and practical applications,” Allen says.

A dedicated technical support team is also available to assist with the setup and operation of the Machine Trainer, and to provide customizable training options.

The HxGN Machine Trainer is now globally available, supporting three- to five-axis CNC machine tools, mill-turn machining and CMM training with up to two CNC controllers per unit. It features digital twins for Hermle, DMG and Fanuc machines. CMM support includes the Hexagon TIGO SF and other models via the I++ Simulator, using QUINDOS or PC DMIS software. Customers can also request a digital twin for any machine.