Industrial IIoT, AI & Digital Twin Specialists

IoT & Digital Twin
Solutions for the
Industrial Edge

We design end-to-end IoT solutions and Digital Twin platforms — connecting LoRaWAN networks, IIoT devices and satellite backhaul to AI‑powered digital replicas of mines, farms, cities, energy networks and heritage buildings.

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Physical asset Digital twin IoT telemetry Satellite uplink

[ 01 ] INDUSTRY FOCUS

Built for asset-heavy industries

Six sectors where sensor data, physical assets and uptime meet — the places a live Digital Twin pays for itself fastest.

Illustrative footage

The challenge Unplanned downtime halts production

With IoT + digital twins Predict failures 24–72h ahead

  • Predictive maintenance
  • Safety telemetry
  • Fleet visibility
See predictive maintenance →
Animated open-pit mine twin: a haul truck and excavator stream telemetry to a LoRaWAN mast

Mining

Predictive equipment monitoring, safety telemetry, and resource optimisation across underground and open-cut operations.

Animated precision agriculture: a drone scans crop health over soil-moisture sensors

Agriculture

Precision farming via soil, climate, and crop sensors; AI-driven irrigation and yield forecasting at scale.

Animated bridge monitoring: strain sensors on the cables and a live strain signal as traffic crosses

Smart Infrastructure

City-scale asset management, energy grid intelligence, and building automation backed by real-time Digital Twins.

Animated smart city: a rooftop sensor mesh relays data across the skyline

Smart City

Connected urban infrastructure — traffic, utilities, public safety, and environmental sensors unified into a city-wide Digital Twin for real-time management.

Animated smart energy: turning wind turbines and a solar array feed live generation to a substation

Smart Energy

Grid intelligence, renewable asset monitoring, and energy optimisation using IIoT sensors and AI-driven Digital Twins across generation, distribution, and storage.

Animated heritage monitoring: a laser scan builds a point-cloud twin while a crack sensor watches a column

Heritage Buildings

IoT structural and environmental monitoring to preserve historic assets — tracking moisture ingress, micro-vibration, and settlement to prevent irreversible damage.

Our Speciality
[ 02 ] PLATFORM INTELLIGENCE

One Pane of Glass: Sense, Predict, Explain, Act

IoT sensors stream live data, AI models forecast failures before they happen, an LLM copilot explains why in plain English, and the Digital Twin shows it all on one screen — so your team acts on a planned stop instead of an emergency.

Interactive preview · sample data
  1. 01SenseIoT & edge
  2. 02PredictAI models
  3. 03ExplainLLM copilot
  4. 04ActTwin & workflow
Synapse Edge · Engine E1 — Ground run Maintenance planned
01 IoT streams Engine E1 · 64 sensors
  • Fan vibrationAccelerometer · No. 1 bearing 14.8 mm/s
  • Fan speed N1Speed probe · fan shaft 95.0 %
  • Turbine gas tempThermocouple harness 860 °C
  • ThrustTest-stand load cell 334 kN
Edge gateway GW-01 · live · 180 ms to twin
Digital twin Model · Shadow · Twin
Digital twin of a turbofan engine on a ground-run test stand, cut away to show the fan, compressor, combustor and turbine at take-off power
synced · every sensor mapped to its asset
02 AI prediction Engine E1 fan
now vibration limit ≈ 38 h −36 h+48 h
Time to limit
38 h
Confidence
91%
Likely cause
Fan imbalance (energy at 1× N1)
03 Operations copilot LLM · grounded in your data

Why is engine E1 vibrating, and what should we do?

E1's fan vibration at take-off power has climbed from 4.8 to 14.8 mm/s over the last 36 engine hours, with the energy at 1× N1, the fan's own speed. That points to fan imbalance, not a bearing defect: turbine gas temperature, oil pressure and the core-speed spectrum are all normal. At this rate it reaches the 18 mm/s limit in about 38 engine hours. I recommend a fan trim balance at Tuesday's overnight check, and I've drafted work order WO-2187.

Sources: E1 vibration spectrum · engine logbook · OEM fan balance procedure
04 Act CMMS work order
WO-2187 Fan trim balance · engine E1
  1. Drafted by AI copilot
  2. Approved by maintenance control
  3. Scheduled · Tue 23:00 overnight check

Result: balanced in a planned slot — no unscheduled engine removal.

[ 03 ] WHAT WE DO

End-to-End IoT & Digital Twin Solutions

From sensor hardware to intelligent simulation — we architect complete IoT solutions and Digital Twin platforms so your operations become self-aware.

01

IoT & Sensor Integration

We design and deploy robust IIoT architectures using LoRaWAN, MQTT, OPC-UA, and Modbus — from sensor selection to cloud ingestion pipelines.

  • LoRaWAN network design & deployment
  • Edge gateway configuration (AWS IoT, Azure IoT Hub)
  • Real-time telemetry & SCADA integration
  • Industrial protocol bridging
Discuss your project →
02

AI & Machine Learning

We build domain-specific AI models — from predictive maintenance algorithms to multimodal LLMs that make sense of complex operational data.

  • Predictive analytics & anomaly detection
  • Computer Vision for industrial inspection
  • Custom LLM fine-tuning & RAG pipelines
  • On-device edge ML model deployment
Predictive maintenance & vibration monitoring → Discuss your project →
03

Digital Twin Development

We create high-fidelity 3D digital replicas of your physical assets, synchronised in real-time to your sensor network for simulation and prediction.

  • 3D asset modelling & physics simulation
  • Real-time sensor data synchronisation
  • Scenario planning & what-if analysis
  • Unity / Unreal / NVIDIA Omniverse builds
Discuss your project →

Not sure which service fits your challenge?

Schedule a Free Technical Audit Take the Free Readiness Scorecard

Not ready to talk? Score your Digital Twin across 16 dimensions in two minutes — no call required.

[ 04 ] DIGITAL TWIN TECHNOLOGY

Your Physical Assets,
Mirrored in Real-Time

Every sensor pulse, every machine state, every process variable — streamed continuously into a living, breathing 3D digital replica. Simulate failures before they happen. Run what-if scenarios without touching real equipment.

Want to build one yourself? Our IIoT Digital Twin SaaS platform lets you connect live sensor data from InfluxDB, PostgreSQL, MySQL or Grafana, place hotspots, replay history, and view your twin in AR/VR — all in the browser.

Sub-second data latency Sensor-to-model sync under 200ms via edge preprocessing
Physics-accurate simulation Thermal, mechanical, and fluid dynamics modelled in Omniverse / Unreal
Predictive failure horizon AI models forecast anomalies 24–72h before equipment failure
Platform Tour — Your Digital Twin in 65 Seconds
Subtitled 1:05
Read the transcript

Meet the Synapse Edge IIoT Digital Twin Platform — your 3D models and your live sensor data, one living digital twin. Start by pasting a link to any GLB or glTF 3D model: a machine, a building, a whole production line — up to fifty models in one scene. Connect InfluxDB, PostgreSQL or MySQL directly, or link the Grafana you already use; both work side by side. Click the model to pin live sensor hotspots — green, amber or red by your thresholds — or colour a whole component by its live value. Replay up to seven days of history to see exactly how a problem developed. Ask the built-in AI assistant about your readings. On Pro, operate equipment from the model, with supervisor approval and an emergency stop. Walk around your twin in AR, or step inside it in VR. Share a secure link, or embed it in your Grafana dashboards. No code, no infrastructure to manage, and a free plan to start — request your free invitation at synapseedge.co.uk.

[ 05 ] OUR APPROACH

From Physical Reality to
Digital Intelligence

1

Technical Audit

We assess your existing infrastructure, data sources, connectivity, and operational goals to build a precise problem statement.

2

Architecture Design

We produce a detailed IoT-to-AI architecture blueprint — stack, protocols, data flows, model selection, and KPIs.

3

Build & Integrate

Sensors to cloud to AI model. We handle deployment, integration, and validation against your operational environment.

4

Monitor & Optimise

The Digital Twin evolves with your operation. We provide ongoing model retraining, insight dashboards, and alerting systems.

[ 06 ] TRAINING & COACHING

IoT & Digital Twin
Training & Workshops

We design and deliver hands-on IoT and Digital Twin training for engineering teams — intensive technical workshops covering the full spectrum from IoT fundamentals to advanced AI and Digital Twin implementation. Training is bespoke — shaped around your technology stack and industry context.

Animated workshop bench: a sensor streams through a dashboard into a live digital twin — IoT & Digital Twin Workshop 1 Day
Flagship · Hands-On

IoT & Digital Twin Workshop

Connect real sensors, stream live data, and build a working Digital Twin — in a single day. Our flagship hands-on intensive.

SensorsMQTT3D TwinDashboards
View workshop details →
Animated IIoT stack: sensor to gateway over LoRaWAN, then MQTT to the cloud — IIoT Foundations course 1 Day
Intermediate

IIoT Foundations

The full IoT stack — sensor selection, LoRaWAN, MQTT & OPC-UA, edge gateway configuration, and cloud ingestion.

LoRaWANMQTTOPC-UAAWS IoT
See dates & book →
Animated sensor time series with a detected anomaly and forecast band — Applied AI for Engineers course 2 Days
Intermediate

Applied AI for Engineers

ML theory to production-ready models on industrial time-series data — predictive maintenance, LLM integration, and edge AI.

TensorFlowONNXLLMEdge AI
See dates & book →
Animated physical asset and wireframe twin syncing in both directions — Digital Twin Design course 2 Days
Advanced

Digital Twin Design

Architecture-led training on designing, building, and operating Digital Twin systems — cyber-physical modelling and real-time sync.

BIMSimulation3D VizReal-time
See dates & book →
Animated roadmap from audit to pilot, scale and ROI — Leadership Briefings Half Day
Executive

Leadership Briefings

Strategic technology briefings for CTOs and Operations Directors — ROI frameworks, governance, build-vs-buy, and roadmap planning.

ROIGovernanceStrategyRoadmap
See dates & book →
Animated: an AI agent reads live telemetry, reasons, and raises a work order behind an approval guardrail — AI Agents for Industrial Operations 1 Day
New · Runs Monthly

AI Agents for Industrial Operations

Agents that read live telemetry, reason about asset condition and raise work orders — with the guardrails safety-critical plant demands.

Tool CallingRAGGuardrailsCMMS
See dates & book →
Animated n8n workflow: a webhook triggers an AI agent that calls tools and writes to the CMMS — Building AI Agents in n8n 1 Day
New · Intermediate

Building AI Agents in n8n

Agents that use tools, hold context and take multi-step action — built visually in n8n and running by the end of the day.

n8nAgentsMemoryVector Store
See dates & book →
See public dates & book→ Request a Training Proposal

Public workshops run in the last week of every month — AI agents and n8n automation in odd months, IoT and Digital Twin in even months. Maximum 10 seats. Every course is also delivered privately, at full length, on your own systems.

Client story

From the workshop to a working digital twin

I started with the basics of Digital Twin technology and then had the opportunity to bring this knowledge back to the SustFridge team, where we put it into practice.

Their Digital Twin platform has been very useful for our project, and I look forward to more opportunities to work together in the future.

Dr Hasila JarimiResearcher in Thermal Energy Storage · Marie Skłodowska-Curie Fellow
Read Hasila's post on LinkedIn ↗
SustFridge Digital Twin dashboard in Grafana: a 3D model of the solar-powered fridge with live sensor hotspots, twin and manual control modes, and battery and power gauges
The SustFridge twin, embedded in the team's Grafana dashboard. Image: Hasila Jarimi, LinkedIn.
IoT & Digital Twin training · SustFridge

From a Digital Twin workshop to a live twin of a solar-powered fridge

The project
SustFridge — a solar-powered fridge that uses phase-change material (PCM) as a thermal battery. A collaboration between SERI UKM, the University of Nottingham, PCM Products Ltd and UNDIP.
The training
Hasila attended Synapse Edge Digital Twin training as part of her Marie Skłodowska-Curie Fellowship, then brought it back to the project team.
The result
A working Digital Twin (Model–Shadow–Twin) over a LoRaWAN architecture with M5Stack hardware, combining the solar PV, refrigeration and PCM battery in one live 3D view — monitored, visualised and controlled remotely on the Synapse Edge platform to optimise PV energy use.
  • LoRaWAN
  • M5Stack
  • Grafana
  • Synapse Edge platform
  • Remote control
Trading as Synapse Edge Ltd
Team Expertise LPWAN · IoT/IIoT · AI · Digital Twins
Combined Experience 40+ years across 3 sectors
[ 07 ] ABOUT US

The Edge Philosophy

"The Edge" refers to the precise boundary where the physical world meets the digital — where raw sensor data transforms into operational intelligence.

We are a specialist team of engineers, AI researchers, and industry domain experts — united by a single focus: bridging the physical-to-digital gap with genuine technical rigour. Our team brings decades of combined experience in embedded systems, wireless sensor networks, industrial AI, and high-fidelity simulation.

We work directly with CTOs, Operations Directors, and Engineering Leads who need more than a slide deck. They need a technical partner who can design, build, and validate a complete physical-to-digital system — and explain every decision with precision.

⬡ PhD-Level Technical Depth
⬡ Multi-Discipline Expert Team
⬡ End-to-End Ownership
⬡ No Marketing Fluff

Dr. R. Sajad

Founder & Lead Architect

15+ years in BIM and smart building monitoring.

Architecture IoT Digital Twin

AI Research Lead

ML & Computer Vision

MSc Machine Learning. Specialises in on-device inference, LLM fine-tuning, and industrial anomaly detection.

LLMs Computer Vision Edge AI

Digital Twin Engineer

3D Simulation & Real-time Sync

10 years building high-fidelity digital twins for mining and infrastructure using Omniverse and Unreal Engine.

NVIDIA Omniverse Unreal Engine Physics Sim

Domain Consultant

Mining & Agriculture Specialist

20 years operational experience in mining and precision agriculture. Bridges technical design and real-world deployment.

Mining Ops Precision Ag SCADA
[ 08 ] FAQ

Frequently Asked Questions

What IoT and Digital Twin training workshops do you offer?

We run two tracks. Public one-day workshops take place in the last week of every month, with a maximum of 10 seats: AI & automation topics (n8n Fundamentals, LLMs Beyond the Chat Window, Building AI Agents in n8n, Building Production AI Agents, Applied AI for Engineers) in odd months, and IoT & Digital Twin topics (IIoT Foundations, IoT & Digital Twin Hands-On, Digital Twin Design, Leadership Briefing) in even months. AI Agents for Industrial Operations runs every month. Every workshop is also delivered privately at full length, on your site or remotely, rebuilt around your own stack.

Do you deliver IoT and AI training on-site in the UK?

Yes. Public scheduled workshops run live online, and every workshop is also delivered privately on-site at client premises across the UK or remotely. Private delivery is bespoke — full length, customised to your industry sector and technology stack.

What industries do you provide IoT consultancy for?

We specialise in six sectors: Mining (predictive equipment monitoring, safety telemetry), Agriculture (precision farming, soil sensors, yield forecasting), Smart City (connected urban infrastructure, city-scale Digital Twins), Smart Energy (grid intelligence, renewable asset monitoring, energy optimisation), Smart Infrastructure (building automation, asset management), and Heritage Buildings (structural and environmental IoT monitoring to preserve historic assets).

What is a Digital Twin and how does Synapse Edge build one?

A Digital Twin is a real-time 3D digital replica of a physical asset, synchronised continuously via IoT sensors. Synapse Edge architects the full pipeline: sensor deployment, edge processing, cloud ingestion, AI modelling, and high-fidelity 3D visualisation using NVIDIA Omniverse or Unreal Engine — with sub-second data latency.

Do you offer a Digital Twin software platform?

Yes. The Synapse Edge™ IIoT Digital Twin Platform is a browser-based SaaS product that turns your 3D models into live digital twins. Connect directly to InfluxDB, PostgreSQL or MySQL, or use your existing Grafana instance, then place live sensor hotspots, replay history, control equipment, and view in AR/VR. You can even embed the twin into a Grafana dashboard via iframe. It is currently invite-only with a free plan — request access on our platform page.

[ 09 ] GET IN TOUCH

Ready to Bridge the
Gap?

Tell us about your challenge. Whether you need an IoT architecture review, an AI proof-of-concept, or a complete Digital Twin build — we'll respond with a technical perspective, not a sales pitch.

Email Use the contact form →
LinkedIn Synapse Edge Ltd ↗
Calendly Book a 30-min Consultation ↗

We respond within 1 business day. No spam, ever. We never sell your data.