OpenPLC vs TwinCAT
Comprehensive comparison of two leading PLC programming platforms
OpenPLC
OpenPLC Project (Open Source)
Completely FREE - no costs ever
TwinCAT
Beckhoff Automation
FREE engineering software - only pay for runtime
Overall Winner
TwinCAT leads with an overall score of 77/100
TwinCAT is the stronger overall choice with better community support. However, OpenPLC may be preferable if you prioritize pricing or if you're already committed to the OpenPLC Project (Open Source) ecosystem.
Score Breakdown
| Category | OpenPLC | TwinCAT |
|---|---|---|
| Overall | 55 | 77✓ |
| Pricing | 100✓ | 95 |
| Ease of Use | 50✓ | 40 |
| Features | 63 | 86✓ |
| Industry Adoption | 18 | 70✓ |
| Community Support | 94 | 99✓ |
| Career Value | 23 | 75✓ |
Real-World Scenario Recommendations
See how OpenPLC and TwinCAT perform in specific industry scenarios to help guide your decision.
Small Machine Builder
OEM building compact machines with 50-200 I/O points, typically for niche markets or specialized applications
OpenPLC
Interesting for proof-of-concept or extremely budget-constrained startups, but risky for commercial machines. The appeal is obvious: completely FREE, runs on Raspberry Pi ($35-$100 hardware cost), zero licensing restrictions. Perfect for: (1) Building your first prototype to secure investor funding, (2) Educational machines or demonstration units, (3) Very simple control tasks with forgiving indus...
TwinCAT
Intriguing choice for engineering-savvy small OEMs, particularly if you need exceptional motion control. The licensing model is perfect for small builders: Engineering software is completely FREE - you only pay for runtime licenses on target hardware ($0-$3,000 per machine). This means zero upfront investment to develop your first machine. If you build 10 machines, you pay 10 runtime licenses. Bui...
Key Considerations:
- •Per-machine software licensing cost vs expected production volume
- •Time-to-market pressure - can you afford 6+ month learning curves?
- •Target customer geography and brand preferences
- •Hardware cost optimization - some platforms offer cheaper controllers
Automotive Tier 1 Supplier
Tier 1 automotive supplier providing systems and components directly to OEM vehicle manufacturers (VW, BMW, GM, Ford, Toyota, etc.)
OpenPLC
Not viable for automotive Tier 1 production equipment. Automotive OEMs have strict certification, safety, and vendor support requirements that OpenPLC cannot meet. Insurance, liability, and customer acceptance issues eliminate this option. Possibly acceptable for internal R&D labs, proof-of-concept demonstrations, or training junior engineers before expensive platform licenses. Otherwise, avoid fo...
TwinCAT
Specialized choice for automotive Tier 1 suppliers focused on testing equipment, dynamometers, or advanced motion control applications rather than assembly lines. Beckhoff TwinCAT excels in: engine test stands (precise motion and data acquisition), suspension testing rigs, battery testing systems, and automated quality inspection with high-speed vision. The PC-based architecture provides computing...
Key Considerations:
- •Customer-specified platforms are non-negotiable - verify before any engineering investment
- •Long-term parts availability (15-20 years) is critical for automotive
- •Safety certifications (SIL 2/SIL 3) must be well-established and accepted
- •Customer's plant maintenance teams must be trained on your platform
Process Industry (Chemical, Oil & Gas, Pharma)
Continuous process control in chemical plants, refineries, pharmaceutical manufacturing, and other process industries requiring high reliability and regulatory compliance
OpenPLC
Completely unsuitable for process industries. The lack of safety certifications, redundancy, regulatory compliance documentation, and vendor support eliminates OpenPLC from consideration. Process industries cannot accept uncertified control systems due to safety, environmental, and regulatory requirements. Not viable even for non-critical applications in regulated environments.
TwinCAT
Niche applications in process industries, primarily for specialized high-speed data acquisition, advanced process analytics, or precision motion control in pharmaceutical packaging. The PC-based architecture provides computing power for real-time process calculations and optimization algorithms that exceed typical PLC capabilities. The MATLAB/Simulink integration enables model-based control strate...
Key Considerations:
- •Redundancy and high availability are mandatory for critical processes
- •Safety certifications (SIL 2/SIL 3) for emergency shutdown systems
- •Long-term vendor support (20-30 year plant lifecycles)
- •Integration with process instrumentation and field devices
💰Pricing Comparison
OpenPLC (free) is significantly more affordable than TwinCAT ($). OpenPLC costs between $0 and $0, while TwinCAT ranges from $0 to $3 000.
📚Learning Curve
OpenPLC (rated 6/10) is easier to learn than TwinCAT (rated 7/10). OpenPLC typically takes 3-6 months to learn, while TwinCAT requires 6-12 months. This makes OpenPLC better for beginners.
⚙️Features & Capabilities
OpenPLC offers 11 key features. TwinCAT provides 11 key features with safety programming, motion control, robotics integration. Both platforms offer a comprehensive feature set for industrial automation.
🏭Industry Adoption
TwinCAT has 60% market adoption compared to OpenPLC's 10%. TwinCAT dominates in Europe, North America, Asia-Pacific, while OpenPLC is strongest in Global (primarily education and research). TwinCAT's higher adoption means more job opportunities and community resources.
🔌Hardware Compatibility
OpenPLC is designed specifically for Generic/Open Hardware hardware, while TwinCAT works with Beckhoff PLCs. Both are vendor-specific solutions optimized for their respective hardware ecosystems.
💼Career Prospects
TwinCAT offers stronger career prospects with 60% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, TwinCAT expertise is more in-demand.
OpenPLC Overview
Key Strengths
- ✓Completely FREE - no costs ever
- ✓Open source - fully customizable
- ✓Runs on inexpensive hardware (Raspberry Pi)
- ✓Perfect for learning without financial investment
Limitations
- ✗Not suitable for commercial/industrial use
- ✗No official support (community only)
- ✗Limited features compared to commercial PLCs
Best For
TwinCAT Overview
Key Strengths
- ✓FREE engineering software - only pay for runtime
- ✓Exceptional motion control capabilities
- ✓PC-based architecture provides high performance
- ✓Excellent real-time performance with EtherCAT
Limitations
- ✗Steep learning curve
- ✗Requires strong PC/Windows knowledge
- ✗Less common than Siemens/Rockwell (fewer jobs)
Best For
Recommendations
For Beginners
Both are suitable
For Professionals
TwinCAT
Budget-Constrained
Both are suitable
Enterprise Use
TwinCAT
Frequently Asked Questions
Which is better: OpenPLC or TwinCAT?
TwinCAT is the stronger overall choice with better community support. However, OpenPLC may be preferable if you prioritize pricing or if you're already committed to the OpenPLC Project (Open Source) ecosystem.
What is the price difference between OpenPLC and TwinCAT?
OpenPLC (free) is significantly more affordable than TwinCAT ($). OpenPLC costs between $0 and $0, while TwinCAT ranges from $0 to $3 000.
Which is easier to learn: OpenPLC or TwinCAT?
OpenPLC (rated 6/10) is easier to learn than TwinCAT (rated 7/10). OpenPLC typically takes 3-6 months to learn, while TwinCAT requires 6-12 months. This makes OpenPLC better for beginners.
Which has better career prospects?
TwinCAT offers stronger career prospects with 60% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, TwinCAT expertise is more in-demand.