What defines the aerospace industry? Precision, safety, and a constant drive for innovation all come to mind. As manufacturers face increasing pressure to deliver more complex and customized products, advanced simulation techniques are offering a way to streamline production, reduce costs, and improve efficiency by testing and refining processes in a virtual environment before they get implemented on the factory floor.
Digital Twin Technology
A digital twin is an exact virtual replica of a physical system or process, and in aerospace, this technology allows engineers to create a digital version of an aircraft component or even an entire production line to simulate different manufacturing scenarios.
With simulation, you can also evaluate how different materials, configurations, and assembly techniques will perform under various conditions. With data in hand, your engineers can now optimize designs for durability and performance without having to go through multiple rounds of expensive physical testing.
Augmented Reality and Virtual Reality
Augmented reality (AR) and virtual reality (VR) provide immersive experiences that enhance training, design, and production processes. AR in particular enables workers to access real-time, contextual data directly within their line of sight, allowing them to make faster and more accurate decisions. In a manufacturing environment, AR can provide detailed, step-by-step instructions for complex assembly tasks.
Technicians use AR headsets or mobile devices to view holographic overlays right on physical components, so they can see exactly where parts need to be installed or how machines should be assembled. What this means for manufacturing is reduced margins of error and the freedom to use less experienced workers at a higher level, where they’re learning as they produce. Furthermore, AR can offer real-time feedback, which means the technicians are alerted at the moment if a part is misaligned or a process step is missed. That means a lot less rework and fewer delays.
Virtual reality, on the other hand, allows you to simulate production processes in a fully immersive 3D environment. VR can be used to create virtual assembly lines, so workers can practice and perfect their skills in a risk-free setting.
Simulating Supply Chain and Logistics
The global aerospace supply chain is wildly complex, involves multiple suppliers, often has long lead times, and is subject to some of the world’s most intense regulatory requirements. Disruptions at any stage mean huge delays and increased costs. By using simulation software to model supply chains, you can better predict potential disruptions and identify opportunities for improvement.
For example, simulations can evaluate how the performance of different suppliers will impact the overall production schedule, so you can design the most efficient routes for delivering parts and materials. These models also allow you to proactively address bottlenecks and adjust strategies to avoid delays, create contingency plans for various scenarios like supplier shortages or shipping delays, and figure out how you’d continue production even in the face of an unexpected challenge.
Real-Time Data and IoT
By embedding sensors into equipment and systems throughout the production process, you get a wealth of real-time data on everything from machine performance to environmental conditions. This data is then fed into advanced simulation software, allowing you to create highly accurate models that reflect the actual conditions on the factory floor.
IoT data also enhances predictive maintenance and operational efficiency. By continuously monitoring machines and equipment, you can predict when maintenance will be required and get insights into how production lines will be affected by machine malfunctions or maintenance activities, so you can plan for adjustments in production schedules accordingly. Use IoT systems to optimize energy consumption, machine utilization, and overall process efficiency, as well, to cut costs and reduce environmental impacts.
Workforce Efficiency and Training
The aerospace industry is facing a skills gap. Many experienced technicians are ready to retire, and newer employees often lack the in-depth knowledge required to handle the complexity of modern production lines. AR can help bridge this gap by providing workers with real-time guidance and training on the job.
Beyond assembly tasks, AR can also be used for remote collaboration and troubleshooting. When technicians encounter a problem they can’t solve on their own, AR allows them to connect with more experienced colleagues or specialists, regardless of location. Through AR-enabled remote assistance, experts can see exactly what the technician is working on and provide guidance as though they were there in person. This speeds up problem resolution and reduces the need for expert technicians to be physically present at every manufacturing site.
Improving Quality Control
Even the smallest defects can have serious safety and financial implications in aerospace. Advanced simulation techniques are revolutionizing how manufacturers approach quality assurance by allowing them to test and refine their processes virtually, before any physical parts are produced. Digital models can simulate the behavior of materials, parts, and assemblies under various conditions so you can identify potential issues early in the design and production phases.
You can also virtually test designs against real-world conditions, such as high-altitude pressure, extreme temperatures, and mechanical stress and then refine designs as much as needed before moving to physical production. You can also test a broader range of conditions than would be feasible with physical testing alone. Virtual testing allows for faster iterations and more comprehensive evaluations, as well, since you can simulate the entire lifecycle of a part, from its initial production through years of use in an aircraft.
At SAABS RDS, we’re committed to helping aerospace manufacturers stay competitive in a very fast-paced industry. By offering expertise in digital transformation, advanced simulations, and IoT integration, we help companies adopt and implement these innovative techniques. Contact us today at SAABS RDS to learn more.