In modern manufacturing, the ability to accurately model and analyze serialized parts and assemblies is crucial for ensuring quality and performance. The Digital Twin also demands that there exists a digital counterpart for every product that is physically created. This presentation explores an approach that leverages Isogeometric Analysis (IGA) and unstructured spline representations to map nominal CAD geometry onto part-specific geometry using point cloud data to create accurate geometric representations of manufactured parts. This allows the direct incorporation of real-world geometric deviations from the nominal design facilitating detailed analysis and optimization of each individual component and assembly. In this goal, Raytheon and Coreform are working to develop capabilities that enhance both design and analysis workflows for the Digital Twin. We will discuss the process of capturing point cloud data and its use in creating an ‘as built’ CAD representation of that scanned part. The presentation will demonstrate how this approach allows for seamless modeling and analysis of serialized parts, which would enable more robust inquiries into failure analysis and performance of ‘out of tolerance’ parts. By the end of the session, attendees will gain insights into an additional potential of IGA by leveraging the spline representation of as designed and as manufactured geometry, reinforced by the collaborative efforts with Coreform. This underscores the importance of advanced computational techniques and vendor partnerships in the era of digital transformation and their crucial role in realizing the full potential of the Digital Twin concept.