From safety to data-driven design: How VR is improving manufacturing efficiency

Virtual reality (VR) is helping manufacturers safely accelerate training, launch immersive reviews and deliver data-driven design – all of which boosts the bottom line.

For example, VR learning experiences are already accelerating training, developing teams' skills at scale in new ways. Whereas in-person safety training may require full factory shutdowns, affecting businesses' schedules and production, simulating dangerous scenarios in virtual reality provides employees the opportunity to practise in a safe space. In fact, Forrester Consulting research shows that 75% of manufacturing leaders agree that mixed reality (MR) helps their organisations train employees for dangerous situations in a low-risk environment.¹

Then, from sales pitches to plant tours, immersive VR content is bringing concepts to life, making the complex easy to understand. Digital twins enable teams to see how people are interacting with a space, unlocking further immersive learning experiences and saving costs.

The technology is being used across the manufacturing industry. Here, we focus on its benefits for welding, engineering and agriculture.

Transforming the welding workshop in VR

VR is augmenting manufacturing practices across training, design and production. For example, VR welding simulators provide a safe, risk-free environment for trainees to practise welding techniques without exposure to hazards such as burns, fumes or electric shock.

Compared to traditional welding training, augmented reality (AR) can save material, time and infrastructure. Haptic feedback and gesture-based controls in VR can also simulate the tactile experience of welding, improving practical abilities essential for real-world performance. In one meta-analysis of 42 studies on VR and AR welding training research, researchers found that workshops leveraging the technology had the most impact for the low to intermediate welding positions, boosting cognitive development and psychomotor skills. This included one VR intervention group that performed better than a traditionally trained group, with an increase of 41.6% in overall certifications earned.

In an industry facing a deficit of skilled workers, VR could help quickly upskill welding trainees from novices to intermediate at scale.³ In fact, Forrester Consulting research shows that 93% of manufacturing leaders report that it takes less than an hour to orient employees to MR.⁴

Through training platforms such as SkillsVR, ThingLink and Uptale, businesses can create immersive training that fast-tracks learning and development. This approach also reduces the need for consumables such as metal, gas and electrodes, minimising production downtime.

Recreating the factory floor – and the factory – in VR

VR is also enabling engineers to visualise, simulate and plan via 3D models before any physical work begins. Potential issues can be flagged in pre-production, significantly reducing time and costs, through digital twins: virtual replicas that enable life-sized walkthroughs, detailed inspections and real-time modifications. Compared to physical site inspections, these can be accessed on demand, whenever and wherever by multiple stakeholders.

For example, construction firm Mortenson created a digital twin of its data centre design. More than 50 stakeholders, spanning four US states and ten different disciplines, were provided with Meta Quest headsets, allowing them to walk through the design and provide feedback on the spot before construction began. In doing so, it saved an estimated $26.5K after more than 600 issues were raised.

The implementation of VR in power plants is also helping to optimise operations, training and safety protocols. Technicians can rehearse maintenance and troubleshooting procedures virtually in a digital twin via apps such as Gravity Sketch. This not only helps to reduce training costs and the risk of errors – given the energy sector is infused with complex infrastructures and critical operations, it helps to create safer workplace cultures.

Immersive training through providers such as ForgeFX, LuminousXR and PIXO VR helps to reduce training time and costs – for example, it eliminates the requirement to put employees on helicopters to reach platforms, or on planes to reach remote or overseas fields to complete training. There is also a significant reduction in harm. For utilities and energy companies, virtual training eliminates exposure to physical hazards such as radiation, high voltage or toxic chemicals. It also lowers the risk of being in settings with safety concerns (e.g. "on tower") before employees are trained and assessment is completed.

The myriad benefits of mixed reality is why the global AR/VR in nuclear power plant market is projected to reach USD 8.8 billion by the end of 2030 – at a compound annual growth rate of 9.8%.⁵

Boosting agriculture through VR

VR in agriculture is also a rapidly expanding field. The technology is providing precision farming, data visualisation and enhanced management. Furthermore, AR is well suited to agriculture: farmers can scan their crops and receive real-time data overlays, down to the minutiae, such as moisture and nutrient metrics.

As agriculture increasingly relies on technology, VR and AR training can provide big benefits to farmers. For example, smallholders who may be unfamiliar with precision agriculture tools – such as GPS systems, drones and soil sensors – particularly in water-scarce regions. Immersive training programmes could help these farmers upskill and learn how precision farming techniques can boost yields and efficiency. Likewise, the technology can simulate region-specific challenges, such as local pests, diseases and climate conditions – ensuring farmers receive relevant, practical education.

VR programmes can also provide an interactive way for farmers to learn the mechanics of various machines, including tractors, harvesters and irrigation systems. Farmers can practise operating these machines virtually, understanding their controls and functions without the risks of damaging equipment or putting themselves in danger. Simulations can then cover machinery maintenance and troubleshooting.⁶

In one meta-analysis of 122 studies, researchers found that VR and AR technologies are already significantly enhancing operator training, improving real-time monitoring and facilitating informed decision-making in agricultural operations.⁷

Unlocking the next phase of manufacturing with VR

VR is transforming manufacturing processes across training, design and production. It helps to upskill novices, optimise workflows, create digital twins and practice real-world scenarios in a risk-free environment. The technology isn't only boosting bottom lines – it's helping to create safer workplaces and deepening the workforce's skills across the industry.

It's one of the reasons why 74% of manufacturing leaders in the Forrester Consulting Research study say that they'll expand its use in the coming years, with nearly 3 in 4 also anticipating that VR will play a bigger role in future learning and development efforts.⁸

Get in touch with Meta for Work

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Keep reading about working in mixed reality (MR):

What is the best VR headset for work?
Using VR to train for the automotive mechanics trade
Six innovations shaping the future of work

Sources

1. A commissioned study conducted by Forrester Consulting on behalf of Meta, April 2025. Base: 108 decision-makers involved in learning and development technology decisions in manufacturing organisations in North America and Europe.
2. "VR and AR virtual welding for psychomotor skills: a systematic review", National Library of Medicine, Feb 2022.
3. "Virtual reality in welding training and education: A literature review", Journal of Agricultural Education, Dec 2023.
4. A commissioned study conducted by Forrester Consulting on behalf of Meta, April 2025. Base: 108 decision-makers involved in learning and development technology decisions in manufacturing organisations in North America and Europe.
5. "AR/VR in Nuclear Power Plant Market Size (2023 – 2030)", Virtue Market Research, Dec 2022.
6. "The Role of Virtual Reality (VR) and Augmented Reality (AR) in Agricultural Training", GlobalLaunchBase, April 2025.
7. "State-of-the-art in real-time virtual interfaces for tractors and farm machines: A systematic review", ScienceDirect, April 2025.
8. A commissioned study conducted by Forrester Consulting on behalf of Meta, April 2025. Base: 108 decision-makers involved in learning and development technology decisions in manufacturing organisations in North America and Europe.