AUBURN HILLS, Mich. – Beneath the bustling Chrysler Technology Center, Stellantis engineers are borrowing technology from video game studios and Hollywood to revolutionize how vehicles are built. The company’s advanced VR lab, strategically positioned near its pilot production facility, blends industrial precision with immersive simulation to help workers assemble vehicles faster, safer, and with greater precision.
Digital Twin Technology Drives Efficiency
Since its 2018 launch, the VR lab has evolved into a state-of-the-art hub featuring motion capture, physics-based part simulations, and digital twin integration. These tools allow engineers to visualize assembly processes in real time, identify potential bottlenecks, and refine workflows before physical production begins. The technology—originally developed for architecture, film, and gaming—now plays a critical role in optimizing plant layouts and reducing operator fatigue.
Ergonomics and Safety Take Center Stage
One of the lab’s most impactful applications is analyzing worker movements to improve ergonomics. By simulating assembly line conditions, Stellantis can adjust platform heights, define optimal reach zones, and refine part-handling techniques. “Virtual reality lets us spot issues before they become real-world problems,” said Tim Fallon, Stellantis’ North America manufacturing chief. The approach has already resolved hundreds of potential production challenges, including optimizing underbody electrical connection processes at key Michigan plants.
From Simulation to Real-World Results
The 40-by-42-foot lab features a dedicated VR space where teams test everything from tool placement to worker posture. Early virtual testing helped establish precise conveyor height requirements at Sterling Heights and Warren Truck plants, preventing costly retrofits and ensuring worker safety. The facility also includes 3D printing for rapid prototyping, accelerating design cycles while minimizing material waste.
Global Expansion of Virtual Manufacturing
As part of a broader digital transformation, Stellantis is rolling out VR technology across its global manufacturing network. The initiative aims to enhance quality control, reduce downtime, and support the automaker’s push toward sustainable, data-driven production. With virtual reality now a cornerstone of its engineering strategy, Stellantis is proving that the future of auto manufacturing isn’t just built on factory floors—it’s being perfected in the digital realm first.
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