Robert Poyner, head of aerospace at Siemens UK, looks at the new frontiers for digitalisation in the sector and explains why we are on the cusp of a new revolution in manufacturing capability.

The relationship between the digital models of components and their physical counterparts has grown closer since CAD/CAE/CAM systems did away with traditional drawing.

Suddenly, models could be created, and prototypes made, with greater speed and sophistication, speeding up the product development cycle. And almost overnight, it became possible to predict with greater certainty how materials would respond to stresses over time, improving risk management and accelerating the development process.

Now, the convergence between the digital and the physical is complete with the adoption of digital twins, meaning we can develop and test prototypes virtually before a single tool is picked up or machine started, significantly shortening the lead time between design and manufacturing.

From prototype to product lifetime

The next step is taking this concept beyond product development – beyond the launch of a new aircraft – to gather data into a virtual model that can provide a comprehensive picture of an asset long after it leaves the production line. 

This is known as a digital thread, and it can deliver far richer insight and enable much better decision making at every stage of an asset’s lifecycle.

They make it possible to directly link all trials and tests made throughout the virtual commissioning and build stages into a single system that then predicts and mirrors the performance of an asset over time, with a digital twin at one end of the thread holding all the data in one, intuitive model.

Instant access to digital histories

Importantly, every nut, bolt, screw and alteration made during the production process can be recorded and stored, in what is known as a digital passport.

This makes it possible to understand the potentially complex implications of any given decision at a glance, opening up a new frontier for already excellent safety standards by placing the digital history of an asset at an engineer’s fingertips.

Take the very rare occurrence of an engine failure, for instance. This technology enables the exact cause of that issue to be identified and passed onto investigating industry bodies months, or even years, earlier than was previously possible, and means technical problems can be identified and fixed much more quickly.

Unlocking this kind of organisation-wide digital integration was a key part of the reason why we developed Siemens Xcelerator – an open digital business platform that enables customers to accelerate their digital transformation easier, faster and at scale.

Towards the industrial metaverse

While digital twins and threads are generally considered ‘state of the art’ now, technology is moving on at pace. And looking ahead, large-scale, digital integration at a supply chain and industry-wide level through the industrial metaverse is just around the corner.

This concept replicates the real world in digital form and uses digital twins, real time data and analytics to completely mirror complex processes, such as an entire factory. It has the potential to revolutionise the way manufacturing and engineering challenges are tackled by bringing together the digital and real worlds at a much more holistic level.

This will make insight sharing and collaboration possible at an unpreceded scale; helping to accelerate the progress of many fundamental industry goals, including sustainability, resilience, decarbonisation, and dematerialisation.

Early adopters – the businesses that decide to lead the way in this next digital frontier - will truly be able to master the big data that underpins manufacturing processes that companies have wrestled with for many years. 

As we know, developments in technology can rapidly outpace businesses’ ability to adopt them. The industrial metaverse concept may feel like a colossal and revolutionary undertaking, but those with the long-term vision for it can identify smaller scale stepping stones towards it. The key is to ensure systems are interoperable and compatible, so that they can eventually be united as one single digital simulation. 

Now is the time for aerospace manufacturers to be gearing up for the next era of Industry 4.0, by reviewing their existing digitisation strategies and ensuring they are prepared to fully reap the benefits of this virtual revolution.

www.plm.automation.siemens.com