This study evaluates the integration of a Digital Twin (DT) virtual model into the ET0917 Programmable Logic Controller (PLC) Applications module, assessing its impact on enhancing learning by simulating car park scenarios beyond the constraints of the physical lab. Aligned with CDIO principles, all labs in ET0917 are designed to bridge theory and practice, equipping students with essential skills in ladder logic programming, I/O device configuration, and automated control system development. The DT virtual lab extends these learning opportunities by providing a dynamic, interactive environment that overcomes the limitations of the standard lab setup. The DT virtual lab was designed incorporating the principles of Self-Determination Theory and Cognitive Load Theory to strategically reduce extraneous cognitive load while deepening student engagement. Survey and interview feedback from students and staff indicated positive responses, with students reporting improved visualization and a stronger grasp of problem-solving concepts. Building on this success, future developments will expand DT technology to incorporate additional scenarios beyond the standard lab setup. This will broaden the scope of learning and application, particularly by simulating future scenarios that are not physically possible. This approach aims to nurture students’ futures thinking competency, preparing them to anticipate and address emerging engineering challenges while strengthening their ability to conceive, design, implement, and operate solutions within the CDIO framework.
