“When hands-on training isn’t possible, this is the next best thing — and in some ways, even better.”
Back in 2017, we were handed a challenge that felt both thrilling and a bit overwhelming: build a complete, fully interactive VR assembly training application from the ground up. Real-time. Realistic. Immersive. And connected to the cloud. No pressure.
The goal? Simulate the entire assembly process of a complex machine, with no shortcuts — down to the last screw. What we ended up with wasn’t just a VR app. It was a full-on virtual warehouse, complete with tools, parts, realistic interactions, and an integrated instruction system that could guide a first-time user through an 8-hour mechanical build.
The system was built on a 3D real-time engine, optimized directly for VR. From day one, the application was designed to feel as close to reality as possible — not just in look, but in behavior. Each of the 4,700+ parts has a physically accurate weight and mass, and they all respond to gravity, collisions, and force just like their real-world counterparts.
To keep things structured, the app is divided into three main systems:
An instruction processor to guide the workflow
A VR interaction system for intuitive, hands-on manipulation
And a full-scale warehouse replica that mirrors a real environment with all tools and components in place.
The experience is built around two key modes:
Learning Mode — where the user follows clear step-by-step instructions, with highlighted parts, tool guidance, and smart prompts to understand each task.
Test Mode — where the training wheels come off. No more highlights, no more cues. The user must assemble the machine from memory. At the end, a scoreboard displays their performance — tracking time, accuracy, and assembly efficiency.
Sections are broken into manageable 30-minute segments, allowing users to train at their own pace without fatigue. The full build takes about 8 hours, providing an in-depth, hands-on learning experience that’s far more engaging than a manual or video tutorial.
What makes this tool even more powerful is its connectivity. The application is cloud-based, and can be linked to systems like SAP, allowing for user logins, progress tracking, and data storage. It’s a complete solution for onboarding, testing, and certification — accessible from VR, desktop, or mobile devices.
And it didn’t stop there. What started as a one-off training simulator evolved into a scalable platform — now used in various industries and adapted for different machines and workflows. All the parts are stored in the cloud, giving constructors and training teams the flexibility to update or customize the tool whenever needed.
Looking back, building this in 2017 felt like a leap into the future. At the time, real-time physics in VR, cloud integration, and interactive instruction systems were still finding their footing. But the results speak for themselves — and today, what began as an experiment is a full-featured, proven system.
