Cybersecurity emerged as a central theme on the second day of the Smart Factory Expo, reflecting its growing importance to the resilience of manufacturing operations. As industrial systems become increasingly connected through digitalisation, the attack surface expands, making robust cyber defences essential. A cybersecurity spokesperson outlined the current threat landscape confronting manufacturers, emphasizing that effective mitigation strategies are not optional but critical to safeguarding operational continuity.
The discussion acknowledged that cybersecurity is only one of several pressures currently reshaping manufacturing. Brexit-related trade complexities, pandemic-driven supply chain disruptions, and persistent shortages of skilled labour have combined to test operational resilience. In the Digital Transformation Solutions Theatre, Paul Calver, CFO of The Data Analysis Bureau, examined lessons learned from COVID-19 and identified top priorities for manufacturers seeking to rebuild. He highlighted the role of a comprehensive digital toolbox, particularly the deployment of artificial intelligence and machine learning at scale, both within production environments and across broader enterprise functions. For organisations hesitant about embarking on digital transformation, Calver stressed the importance of clearly defined first steps to guide the journey.
The concept of the digital twin—often cited alongside digitisation—was explored in depth. While widely recognised as a virtual counterpart to a physical asset or process, its definition remains inconsistent across the industry. Petteri Vainikka, VP of Product Marketing at Cognite, addressed this ambiguity in his presentation on the anatomy of a digital twin. He argued that to unlock its full potential, the digital twin must be approached as a layered technology stack. This perspective enables identification of the core capabilities needed to deliver value, from improving operational efficiency to enabling intelligent, data-driven decision-making. Vainikka outlined criteria for ensuring a digital twin can address high-priority use cases while maintaining the flexibility to expand across diverse data sources, types, and applications.
Sustainability, once considered a secondary concern, has now become a primary driver of corporate strategy. Data scientist Steph Locke of Nightingale HQ discussed how artificial intelligence and accessible digital tools can accelerate sustainable manufacturing. She provided practical examples, including predictive maintenance to reduce waste, defect detection to improve yield, and generative design to optimise material use. Locke also pointed to sustainable IT practices such as adopting paperless workflows, migrating to carbon-neutral cloud providers, and using green software products. “Over the last few days we’ve had some great discussions with manufacturers and it’s been really interesting to see what others are doing in this space. We’ve met some of partners for the first time since COVID too so that’s been great!” she said.
The Expo also coincided with the Digitalising Manufacturing conference, held in a hybrid format for the first time. A significant focus was placed on the evolving definition of “digital skills” and the fragmentation of skills initiatives across the UK and beyond. Sessions examined both domestic and international frameworks, comparing methodologies and identifying lessons that could inform a more unified approach. Discussions ranged from top-down strategies—forecasting future skills needs based on sector demand—to bottom-up approaches that empower individual companies to upskill their workforce in preparation for digitalisation.
Innovation Alley, a long-standing feature of the Expo, continued to showcase emerging technologies expected to reshape manufacturing over the next decade. Alongside the Emerging Tech Pavilion, it offered a concentrated view of advancements in immersive technologies, automation, and materials science. Juice Immersive, known for producing purposeful augmented, mixed, and virtual reality experiences, was among the exhibitors. “Innovation Alley has a vibe of it’s own and it’s really been a vibrant part of the exhibition over the past few days. Within 20 minutes of setting up yesterday we had already had some brilliant conversations which we believe are going to be really valuable for our business going forward. We’ve really enjoyed having the opportunity to showcase our Augmented, Mixed and Virtual Reality solutions for a range of sectors and brands,” the company stated.
The breadth of topics—from cyber resilience and AI-enabled sustainability to the structural foundations of digital twins and the cultivation of digital skills—underscored the multifaceted nature of modern manufacturing transformation.