<p>The defense industry and military organizations have been behind some of the most impactful innovations in recent history, from duct tape (initially developed to seal ammunition crates in WWII and now used for everything) to GPS navigation systems (pioneered by the U.S. Department of Defense in the 1970s). [1] It’s no surprise why: the defense sector has the resources required to accelerate innovation and an urgent drive to advance technologically for ever-evolving combat readiness.</p><p>Today, printed electronics are at the forefront of defense innovation, and technologies like Voltera’s NOVA <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology?utm_campaign=Wevolver&amp;utm_source=webinar&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=direct%20ink%20writing" target="_blank">direct ink writing</a> (DIW) solution are enabling defense organizations to increase vital metrics like efficiency, adaptability, and miniaturization when it comes to both wearables and combat equipment. In a previous article, we looked at several combat wearable applications for Voltera printed electronics, including discreet sensors for health monitoring and wearable heaters. In this article, we are turning to combat equipment to understand how Voltera’s technology can help defense organizations address an increasing demand for advanced integrated electronics that augment equipment functionality without adding bulk. </p><p>The <a href="https://www.voltera.io/products/nova?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=NOVA" target="_blank">NOVA</a> platform, launched by Canadian company <a href="https://www.voltera.io/about/about-us?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=voltera" target="_blank">Voltera</a> in 2022, is a materials dispensing system designed to accelerate the development of advanced flexible circuits and sensors. The process selectively deposits screen-printable inks (i.e., conductive, dielectric, and functional inks) onto a wide variety of substrates, including both rigid and flexible materials. This printing approach eliminates the need for tooling and masks, resulting in faster iteration cycles and greater agility for applications such as electronics development, materials testing, and low-volume production runs.</p><p>In the context of combat equipment, NOVA has the potential to be a game-changer in the development of circuits, sensors, and displays that enhance the functionality of critical military gear, including communication devices, navigation systems, robotics, vehicles, and more. In the following sections, we’ll be looking at a selection of use cases for the electronics printing technology that showcase this potential.</p><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/2COFihlYVos?&amp;wmode=opaque" frameborder="0" style="width:640px;height:460px"></iframe></span><br /></p><h2 id="isPasted">Remote Robotic Control</h2><p id="isPasted">In the field, there are many environments and scenarios that can pose a risk to humans, from underwater equipment repairs, to bomb disposal, to reconnaissance in remote or difficult terrain. In the continual effort to make troops safer and minimize risk, defense organizations are becoming more and more interested in leveraging robots to carry out these challenging and potentially hazardous tasks. </p><p>Electronics printing platforms such as NOVA can play an important role in the development of remotely controlled robotic devices that can operate in these environments, performing reconnaissance and logistical tasks under human control without any risk to human life. </p><p><span class="fr-img-caption fr-fic fr-dib"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1762259608186-Control+Glove+Printed+with+NOVA+used+for+Finger-Level+Motion+Sensing+and+Remote+Control+of+a+Robotic+Hand.webp" style="width:100%px" class="fr-fic fr-dib" alt="Control Glove Printed with NOVA used for Finger-Level Motion Sensing and Remote Control of a Robotic Hand" /><span class="fr-inner">Control Glove Printed with NOVA used for Finger-Level Motion Sensing and Remote Control of a Robotic Hand</span></span></span></p><p id="isPasted">In one relevant use case, NOVA was used to <a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=wearable%20glove" target="_blank">print a wearable glove</a> that remotely controls the movements of a robotic hand.[2] Voltera’s platform printed conductive strain gauges using stretchable silver conductive ink on a flexible TPU substrate. These strain gauges were integrated into a glove and programmed to send haptic signals from the glove to a 3D printed robotic hand, which resulted in the robotic hand mimicking the human hand movements in real time. </p><p>In the defense sector, enabling robots to move and respond in real time based on human input has a number of potential uses, including the remote handling of dangerous materials and hazardous items, like improvised explosive devices (IEDs) and other explosives, conducting maintenance in a high-risk environment, or gathering intel or data from dangerous or hard-to-reach zones such as collapsed structures, underground tunnels, contaminated zones, or active combat areas.. </p><p>In the case of IED disposal, the use of advanced explosive ordnance disposal (EOD)  robots can ensure that the expertise and skill of bomb disposal professionals is still being used, just without any risky proximity. This offers a distinct advantage compared to earlier EOD robots, which are controlled via video-game controllers.[3] In addition to enabling human-controlled actuation interfaces, NOVA can print custom sensors, interconnects, and flexible circuits for the robots themselves, which can be encapsulated in moisture-resistant materials that protect devices from harsh environments.  </p><h2>Electroluminescent Displays</h2><p>Another important application for Voltera’s NOVA solution is in the development of high-quality display technologies, which play a pivotal role in military operations by promoting situational awareness and facilitating how troops and communications operators receive crucial information. It goes without saying that optimal displays for defense applications must offer a combination of clarity and robustness, particularly when used in the field. Electroluminescent displays (ELDs) are thus a perfect fit.</p><p>ELDs are flat panel displays that utilize the principles of electroluminescence—a phenomenon where specific types of material, such as phosphors, emit light when exposed to an alternating current or electrical field. This phenomenon can be harnessed to create displays that are characterized by a thin profile, flexibility, temperature resistance, vibration resistance, overall durability, highly uniform light, and low cost.</p><p>In a defense context, ELDs are already well established due to their high visibility and robustness[4], being used in control panels and instrument clusters in aircrafts, submarines, and road vehicles. ELDs also have great potential in other areas, such as in the production of rugged keypads and portable electronics that require visibility in both dark and light environments.   </p><p id="isPasted"><span class="fr-img-caption fr-fic fr-dib"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1762259655487-NOVA+Printing+a+Multilayer+EL+Display+using+Conductive%2C+Dielectric%2C+and+Phosphor+Inks.webp" style="width:100%px" class="fr-fic fr-dib" alt="NOVA Printing a Multilayer EL Display using Conductive, Dielectric, and Phosphor Inks" /><span class="fr-inner">NOVA Printing a Multilayer EL Display using Conductive, Dielectric, and Phosphor Inks</span></span></span></p><p>Voltera has demonstrated NOVA’s capability for printing electroluminescent displays. In a <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet?utm_campaign=Wevolver&amp;utm_source=wevolver&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=recent-use-case" target="_blank">recent use case</a>, the company printed a blue-light emitting pattern on two different substrates, exploiting NOVA’s ability to print multiple layers. The EL pattern, printed on flexible paper and PET substrates, consisted of four printed layers: a base conductive layer, a dielectric layer, a phosphor layer, and a top conductive layer. When connected to an alternating current, the thin flexible circuit glows blue.[5] Notably, the paper substrate delivered consistent results in the use case, which opens up the door to integrating ELDs into for example uniforms, sensor and vehicle panels, as well as equipment surfaces for covert, durable and low-signature illumination and situational awareness.</p><p>It’s also worth noting that NOVA can also print additional material layers, including optical inks that can add anti-glare properties to a range of displays for glare-resistant maps, control panels, and electronics. </p><h2>Stealth Antennas</h2><p>As communications and tracking devices become more sophisticated, they are also getting smaller and more flexible. These intersecting trends towards greater miniaturization and flexibility in electronics are highly beneficial for the defense industry, which can pack greater functionality into a smaller, more versatile footprint, thus simplifying logistics and deployment without compromising performance.</p><p><span class="fr-img-caption fr-fic fr-dib"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1762259769146-NOVA+Printing+an+RFID+Tag+on+Paper+using+Conductive+Nanocopper+Ink.jpg" style="width:100%px" class="fr-fic fr-dib" alt="NOVA Printing an RFID Tag on Paper using Conductive Nanocopper Ink" /><span class="fr-inner">NOVA Printing an RFID Tag on Paper using Conductive Nanocopper Ink</span></span></span></p><p id="isPasted">Voltera demonstrated this capability by printing an <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=RFID" target="_blank">ultra-high frequency radio-frequency identification (RFID) antenna</a> using a paper substrate and a nano-copper ink. The result of this proof of concept was an RFID tag suitable for long-range reading capabilities with a performance that exceeded off-the-shelf counterparts.[6] In terms of specific application, this type of RFID antenna is largely intended for inventory tracking, which could directly benefit militaries by streamlining the management and tracking of their weapons, communications gear, vehicles, or medical supplies. NOVA can also print antennas with more sophisticated functionality that can be folded to achieve even greater compaction. </p><p>Overall, the possibilities for printed antennas are vast in the defense sector: among other things they can be used in portable surveillance kits, in ultra-high frequency tracking, and to enhance radar evasion for stealth aircraft and vehicles.[7]</p><h2>Conclusion</h2><p>Ultimately, Voltera’s NOVA printing platform has the ability to empower defense organizations as they seek to develop increasingly sophisticated combat equipment while benefiting from production agility and supply chain independence. Using materials dispensing to prototype and develop remote-controlled robotics, EL displays, and compact antennas is just the tip of the iceberg: by putting such a powerful tool in the hands of some of the most innovative minds in defense R&amp;D, the possibilities for new devices are limitless.</p><p>To learn more about NOVA and its defense applications, <a href="https://www.voltera.io/book-a-meeting/nova-demo?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=enhancing-combat-equipment&amp;utm_content=get-in-touch" target="_blank">get in touch</a> with the Voltera team today.</p><h2>References</h2><p>[1] Military inventions that we use every day [Internet]. NATO, 2025. <a href="https://www.nato.int/cps/fr/natohq/declassified_215371.htm" target="_blank">https://www.nato.int/cps/fr/natohq/declassified_215371.htm</a> </p><p>[2] Printing Strain Gauges on TPU laminated on a Glove for Remote Hand Control [Internet]. Voltera, 2025. <a href="https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" target="_blank">https://www.voltera.io/use-cases/white-papers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control</a> </p><p>[3] Thatcher, Cory. Robots to help TF Muleskinner Soldiers counter IED threat [Internet]. U.S. Army, February 22, 2012. <a href="https://www.army.mil/article/74292/robots_to_help_tf_muleskinner_soldiers_counter_ied_threat" target="_blank">https://www.army.mil/article/74292/robots_to_help_tf_muleskinner_soldiers_counter_ied_threat</a></p><p>[4] Monarchie D, Budzilek RA, Cupero F. Sunlight-viewable electroluminescent displays for military applications. InCockpit Displays 1994 Jun 17 (Vol. 2219, pp. 60-67). SPIE. <a href="https://doi.org/10.1117/12.177807" target="_blank">https://doi.org/10.1117/12.177807</a> </p><p>[5] Printing Electroluminescent Ink on Paper and PET [Internet]. Voltera, 2025. <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet" target="_blank">https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet</a> </p><p>[6] Printing an RFID Tag with Copper Ink on Paper [Internet]. Voltera, 2025. <a href="https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper" target="_blank">https://www.voltera.io/use-cases/white-papers/printing-rfid-tag-copper-ink-paper</a> </p><p>[7] Gupta, Srishti. China shrinks jet antenna to 0.047 times wavelength to boost fighter’s stealth power [Internet]. Interesting Engineering, February 26, 2025. <a href="https://interestingengineering.com/military/china-shrinks-jet-antenna-stealth-power" target="_blank">https://interestingengineering.com/military/china-shrinks-jet-antenna-stealth-power</a> </p>

NOVA Printing a Multilayer EL Display using Conductive, Dielectric, and Phosphor Inks

The NOVA platform by Voltera is a versatile tool that can empower defence organizations in the integration of increasingly sophisticated electronics in combat equipment.

Enhancing Combat Equipment with Printed Sensors, Antennas, Displays

<p id="isPasted">In defense, every decision counts. From logistics and supply chains to maintenance and repair operations, there’s little room for error - especially when operating in remote or high-pressure environments. <strong>That’s why reliability is non-negotiable</strong>. As 3D printing becomes more embedded in defense applications, its reliability is being tested in new and critical ways.</p><p>Whether it's producing replacement parts in the field, prototyping critical components, or supporting MRO, 3D printing must deliver consistent results, time after time. In demanding environments - from naval vessels and aircraft hangars to remote operating bases and repair stations - this means the printer needs to function flawlessly despite external challenges like dust, heat, or vibration. This level of reliability is equally essential for maintenance crews working on tight schedules or MRO teams operating in makeshift workshops, where downtime or print failures can delay essential repairs.</p><h2>The cost of downtime in defense</h2><p>When failure isn’t an option, the true cost of downtime becomes clear. A printer issue in a research lab or helicopter maintenance hall can stall innovation, delay essential repairs, or disrupt logistics planning. Beyond reactive repairs, reliable additive manufacturing enables predictive maintenance workflows - producing parts before failure occurs, keeping fleets operational and avoiding delays.</p><p>In many defense MRO settings, aging equipment and parts often requires parts that are no longer in production or only available from a single supplier - a reliable 3D printer allows teams to manufacture those components on demand, avoiding costly delays and dependence on limited supply chains.</p><p>On deployment, those same issues can compromise operations or ground critical equipment. Whether in the field or on base, military operations demand dependable tools that perform under pressure.</p><p>That’s why reliability in defense-focused additive manufacturing goes far beyond rugged hardware. It includes stable software, intuitive workflows for technicians and engineers, broad material compatibility, and predictable maintenance. In every military setting - from R&amp;D facilities to forward operating bases - the entire 3D printing ecosystem must deliver consistent, repeatable results when it matters most.</p><h2>UltiMaker: Built for rugged reliability</h2><p><a href="https://ultimaker.com/3d-printers/s-series/">UltiMaker’s 3D printers</a> are designed and tested to perform in real-world conditions - conditions that reflect the challenges military operations face. With a European engineering heritage and a reputation for delivering professional-grade systems, UltiMaker printers have been deployed across industries where reliability is key for success.</p><p>For defense teams, this translates into a dependable manufacturing tool - whether it's integrated into a logistics hub, supporting rapid prototyping in an R&amp;D lab, or deployed with mobile repair units. UltiMaker printers are known for:</p><ul><li><strong>High print success rates</strong>, even in long, complex builds.</li><li><strong>Compatibility with a wide range of engineering materials</strong>, including wear-resistant and high-strength polymers.</li><li><strong>Compact, modular designs</strong> make them easy to transport and gives the team the flexibility to replace parts when needed.</li></ul><p>UltiMaker’s NATO-compliant printers and European manufacturing standards ensure consistent quality and supply chain transparency - important factors for defense procurement processes.</p><h2>Additive manufacturing with defense in mind</h2><p>In defense operations, reliability also means predictability. Knowing your equipment will work exactly as expected - without needing constant recalibration or specialist oversight - enables faster response times and greater self-sufficiency in the field.</p><p>UltiMaker’s user-friendly interface, reliable firmware updates, and open-material platform help operators stay productive, even when support is limited.</p><p>As 3D printing becomes a critical enabler across the entire defense lifecycle, choosing a system built for reliability is a strategic decision.</p><p><strong>We believe it’s about more than just printing - it’s about accelerating innovation, ensuring readiness, and staying agile in the face of the unknown.</strong></p>

In defense, every decision counts. From logistics and supply chains to maintenance and repair operations, there's little room for error - especially when operating in remote or high-pressure environments. That's why reliability is non-negotiable.

3D printing in defense: Why reliability matters

<p dir="ltr" id="isPasted"><em>Hexagon’s MAESTRO is setting a new benchmark in CMM technology with its fast, user-friendly and fully connected design to meet the real-time demands of aerospace &amp; defence manufacturer. From turbine blades to fuselage components, manufacturers are under pressure to maintain compliance with stringent standards, reduce costs, and respond rapidly to shifting demand.</em></p><p dir="ltr" id="isPasted">In advanced manufacturing environments, precision and responsiveness have become non-negotiable. The Hexagon&nbsp;<a href="https://hexagon.com/products/maestro">MAESTRO</a> Coordinate Measuring Machine (CMM) system, specifically designed for the smart factory era, is redefining quality inspection through speed, simplified operation, and Industrial Internet of Things (IIoT) enabled connectivity. MAESTRO integrates intelligence, automation, and adaptability with a focus on empowering aerospace &amp; defence manufacturers to keep up with escalating production demands and tighter quality requirements. This article explores MAESTRO’s game-changing features, tech innovations, and how it meets the demands of today’s advanced manufacturing.</p><h2 dir="ltr">Why a Digital-First CMM Is Crucial for Aerospace</h2><p dir="ltr">Aerospace manufacturers today need to deliver of backlogs and big order without compromising quality. This requires metrology solutions that can keep pace with rapid manufacturing speeds without becoming a bottleneck. Moreover, the Industry 4.0 principles demand that measurement systems provide smooth digital connectivity, real-time data access, and integration with broader smart factory ecosystems.&nbsp;</p><p dir="ltr">Conventional CMMs often suffer from complex programming requirements that necessitate highly specialized skills, which leads to slower setup and increased risk of human error. Moreover, traditional CMMs tend to operate as isolated units with limited connectivity, resulting in disconnected data silos that impede collaboration and timely decision-making across teams. This lack of integration also limits the ability to implement predictive maintenance or to fully utilize IIoT capabilities. Hexagon’s MAESTRO CMM platform is designed to address all these challenges head-on.&nbsp;</p><h2 dir="ltr">MAESTRO - A CMM Engineered for Advanced Aerospace Manufacturing</h2><p dir="ltr">MAESTRO features an all-digital design optimized for integration with IIoT ecosystems. Its networked architecture facilitates real-time data exchange, remote monitoring, and predictive maintenance. MAESTRO communicates measurement data and functions as a connected node within a broader manufacturing intelligence system. The system is designed for modularity and adaptability, which helps users to customize configurations to suit varying shop floor needs.&nbsp;</p><p dir="ltr"><iframe id="68667653dc03ce52d03a1caf" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/hexagon-cmm-maestro?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><br></p><h3 dir="ltr">Core Specifications</h3><p dir="ltr">MAESTRO is engineered to deliver industry-leading performance with core specifications that set it apart. The CMM achieves measurement speeds up to 1100 mm/s. Rapid probe changeovers further enhance throughput, reducing bottlenecks in production. With its high speed, MAESTRO also maintains high accuracy with a specification of ±1.2 μm plus L/300.&nbsp;</p><p dir="ltr">The system also employs advanced digital sensors that are automatically identified and calibrated upon installation. These sensors provide rich data streams that contribute to the machine’s self-awareness and enable predictive maintenance and real-time performance monitoring. Moreover, MAESTRO’s compact footprint allows it to fit into diverse manufacturing environments without compromising performance. This makes it suitable for integration into both existing production lines and new smart factory setups.</p><h3 dir="ltr">Intelligent Software Ecosystem that solves skilled labor gap</h3><p dir="ltr">MAESTRO’s intelligence is embedded in its software ecosystem, which enhances usability, accuracy, and connectivity. For instance, the digital twin mirrors the physical machine in a virtual environment, enabling offline programming, realistic simulation of measurement routines, and collision protection. PC-DMIS, the globally leading metrology software, integrates seamless with MAESTRO and provides tools for measurement programming, data analysis, and reporting. Similarly, Metrology Mentor is another intuitive software that guides users through measurement processes with assisted no-code workflows. Additional Nexus software, like Metrology Asset Manager, offer cloud-based connectivity and real-time monitoring of machine status, calibration history, and utilization metrics. It enables remote access and management of the CMM fleet, facilitating optimized scheduling, predictive maintenance, and enhanced overall equipment effectiveness (OEE).</p><h2 dir="ltr">The Four Pillars of the MAESTRO Revolution</h2><h3 dir="ltr">Speed</h3><p dir="ltr">MAESTRO delivers the fastest throughput in its class. This high speed is achieved through a combination of high acceleration and movement speed and synchronized wrist and machine axes, which move fluidly and in perfect harmony to accelerate both measurement and setup processes.&nbsp;</p><p dir="ltr">One of MAESTRO’s standout features is its probe changeover capability. Early benchmarks show up to 50% quicker exchange times than with traditional systems. This translates to less downtime between measurement routines and more time spent on productive work. Moreover, accelerated calibration routines, offering up to 85% time savings, ensure that even complex measurement jobs can keep pace with high-speed production environments.</p><h3 dir="ltr">Simplicity</h3><p dir="ltr">MAESTRO’s intuitive user interface and guided workflows, powered by Metrology Mentor software, make the most complex measurement tasks accessible to users of all skill levels. The system’s clear, modern display provides real-time status updates, operator instructions, and warnings, enabling quick, confident decision-making.</p><p dir="ltr">Every aspect of MAESTRO’s design works in concert to remove workflow complexity and reduce the risk of human error. This focus on simplicity ensures reliable, repeatable results and empowers teams to achieve more with less effort.</p><h3 dir="ltr">Connectivity</h3><p dir="ltr">MAESTRO is engineered as an IIoT device from the ground up. Its open platform enables smooth integration with existing industrial automation systems and software environments with no additional hardware required.</p><p dir="ltr">Real-time machine health and performance data are always accessible from anywhere via cloud-based dashboards. Centralized reporting and asset management tools, such as Metrology Reporting and Metrology Asset Manager, facilitate data-driven collaboration and decision-making across teams.&nbsp;</p><h3 dir="ltr">Future-Readiness</h3><p dir="ltr">MAESTRO’s modular architecture and robust technology roadmap ensure that the system can be upgraded in the field at any time, even years after initial deployment. This allows users to add new features or incorporate the latest technologies as their business grows or requirements change.</p><h2 dir="ltr">Next-Gen Technology Driving MAESTRO’s Capabilities</h2><p dir="ltr">MAESTRO is fast and intelligent. It combines a suite of next-generation technologies that simplify complex metrology tasks and ensure consistent measurement results with minimal manual intervention.&nbsp;</p><h3 dir="ltr">Digital Twin</h3><p dir="ltr">MAESTRO utilizes a digital twin, which allows users to program measurement routines offline with high confidence. This digital twin enables realistic simulations of part measurements, including probing paths and collision detection, ensuring validation of programs before actual execution. As a result, first-time-right measurement is achieved, reducing downtime and avoiding costly errors on the shop floor. The digital twin synchronizes instantly with the physical machine and its components, facilitating faster setup and smoother operation.</p><h3 dir="ltr">Smart Machine Eye</h3><p dir="ltr">MAESTRO is equipped with an embedded camera system known as the Smart Machine Eye. It provides remote visual access to the machine during operation and allows operators and support teams to monitor measurements in real-time from any location. It also supports troubleshooting by supplying video recordings in case of unplanned stops or issues.&nbsp;</p><h3 dir="ltr">Metrology Mentor</h3><p dir="ltr">The Metrology Mentor software is an intuitive, assisted workflow tool designed to simplify CMM programming and operation. It enables users of all skill levels to create measurement programs quickly and reliably without needing to write code. The software guides operators through industry-standard compliant GD&amp;T measurements. This approach reduces training requirements and operator dependency, which accelerates throughput and improves overall productivity in quality inspection processes.</p><h3 dir="ltr">Digital Racks &amp; Probes</h3><p dir="ltr">MAESTRO’s hardware ecosystem includes digital racks and probes that are automatically identified and initialized when mounted. This plug-and-play capability removes recalibration requirements when swapping sensors, enabling rapid changes between different measurement tasks or sensor types.&nbsp;</p><p dir="ltr">These advanced technologies position MAESTRO as a highly connected, efficient, and adaptable CMM solution that meets the demands of smart manufacturing environments.</p><h2 dir="ltr">Seamless Integration with the Smart Factory</h2><p dir="ltr">MAESTRO’s architecture is designed for seamless integration into digital manufacturing environments. For instance, MAESTRO provides real-time assessment of machine health, allowing manufacturers to monitor performance trends, schedule maintenance proactively, and maximize uptime. This integration ensures that metrology assets are not isolated components but vital nodes in a broader ecosystem of production intelligence.</p><p dir="ltr">The built-in Metrology Communication Interface (MCI) facilitates integration with automation systems, enabling MAESTRO to be incorporated into automated production lines. This interface supports near-line or in-line integration, allowing the CMM to communicate directly with robotic systems or other automated equipment. As a result, the measurement workflow can be automated easier than ever before.</p><p dir="ltr">MAESTRO’s open digital architecture supports connectivity with major industrial automation ecosystems. This interoperability ensures that quality data from the CMM is integrated into broader manufacturing workflows, facilitating data-driven decision-making and enhancing collaboration across departments. The digital platform also supports remote access and software updates, enabling continuous improvement of the smart factory’s metrology capabilities.</p><h2 dir="ltr">Performance that Grows with Your Business</h2><h3 dir="ltr">Upgrade Pathways: Accuracy+ and Throughput+</h3><p dir="ltr">One of MAESTRO’s standout features is its future-proof, modular architecture. Unlike traditional CMMs, MAESTRO allows users to enhance both accuracy and throughput at any stage of the machine’s lifecycle. The Accuracy+ and Throughput+ upgrade options allow users to boost the system’s precision or speed even years after installation. This flexibility allows users to respond to changing production demands or tighter quality standards without needing a complete hardware overhaul.</p><h3 dir="ltr">Support for Advanced Digital Sensors</h3><p dir="ltr">MAESTRO is designed to keep pace with the rapidly changing sensor technology. The platform natively supports the latest digital sensors, including a tactile scanning sensor or a laser scanner. These sensors enable a broader range of measurement applications and deliver higher data fidelity, allowing users to tackle more complex inspection tasks as the product portfolio diversifies.&nbsp;</p><h3 dir="ltr">The Platform of the Future: Continuous Innovation</h3><p dir="ltr">Hexagon’s commitment to innovation is embedded in the MAESTRO platform. As an all-digital, IIoT-enabled CMM, MAESTRO is built to accommodate future technological advances. The system’s open architecture and robust technology roadmap mean that new software features, automation integrations, and hardware enhancements can be adopted.&nbsp;</p><h3 dir="ltr">Sustainability by Design: EcoMode+</h3><p dir="ltr">MAESTRO incorporates features that help reduce the environmental footprint and promote sustainability. For instance, the EcoMode+ function intelligently manages compressed air and energy consumption, optimizing usage based on operational needs. MAESTRO minimizes resource consumption during idle periods and maximizes efficiency during operation, helping organizations achieve their sustainability goals and reduce utility costs.</p><h2 dir="ltr">Industry Applications: Proven Across Demanding Use Cases</h2><p dir="ltr">In the aerospace and defence sectors, MAESTRO delivers the high-speed and high-accuracy inspection of critical components like turbine blades, rotors, fuselage, tooling &amp; jigs and freeform components. Its ability to adapt to complex geometries and intricate surfaces ensures that all components meet performance specifications without slowing production. Moreover, MAESTRO's compatibility with optical sensors and its advanced design enables fast measurement of aerodynamic surfaces and rotating machinery parts with minimal repositioning, which reduces cycle time.</p><h2 dir="ltr">The MAESTRO Advantage Backed by Hexagon Expertise</h2><p dir="ltr">MAESTRO is the result of Hexagon’s decades-long leadership in metrology and digital manufacturing. It’s supported by Hexagon’s global MyCare service network, offering calibration, software maintenance, and on-demand technical support to ensure system longevity.</p><p dir="ltr">As a key component of Hexagon’s broader Manufacturing Intelligence portfolio, MAESTRO works in concert with other digital technologies to enable smarter design, production, and quality workflows in a connected, autonomous ecosystem.</p><h2 dir="ltr">Conclusion: A New Standard for Aerospace &amp; Defence in Digital CMMs</h2><p dir="ltr">Hexagon’s MAESTRO empowers aerospace manufacturers to enhance quality, reduce costs, and accelerate production by delivering speed, simplifying complex measurement tasks, enabling seamless digital connectivity, and offering a future-proof platform. As more and more industries embrace smart manufacturing, MAESTRO stands out as a critical enabler of this transformation, ensuring that quality inspection is not a bottleneck but a strategic advantage.</p><p dir="ltr">Explore how MAESTRO can help redefine your quality inspection processes by visiting the website: https://hxgn.biz/4j43jC4.</p><hr><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr">Hexagon. [Internet]. Available from:&nbsp;<a href="https://hexagon.com/">https://hexagon.com/</a></p></li><li dir="ltr"><p dir="ltr">Hexagon launches MAESTRO the next-generation Coordinate Measuring Machine. (2025) [Internet] Hexagon. Available from: <a href="https://hexagon.com/company/newsroom/press-releases/2025/hexagon-launches-maestro-the-next-generation-coordinate-measuring-machine">https://hexagon.com/company/newsroom/press-releases/2025/hexagon-launches-maestro-the-next-generation-coordinate-measuring-machine</a></p></li><li dir="ltr"><p dir="ltr">MAESTRO – The all-digital CMM system. [Internet] Hexagon. Available from: <a href="https://hexagon.com/products/maestro">https://hexagon.com/products/maestro</a></p></li></ol>

The new MAESTRO by Hexagon is setting a new benchmark in CMM technology with its fast, user-friendly and fully connected design to meet the real-time demands of aerospace & defence manufacturer.

The CMM System Remastering Aerospace & Defence Metrology with Speed, Simplicity, and Seamless Connectivity

<p data-pm-slice="1 1 []" id="isPasted">The aerospace and defense industry is at a crossroads, facing challenges that demand innovative solutions. From complex supply chains and rising costs to stringent regulatory requirements, traditional approaches are no longer sufficient. Enter digital twin and digital thread technologies—tools that are redefining how aerospace companies design, produce, and maintain their systems.</p><p>If you couldn’t attend the live webinar, you don’t have to miss out. Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width: 100%; max-width: 100%; height: 730px; border: none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><h2><strong>Why Watch This Webinar?</strong></h2><p>In this session, <a href="https://www.wevolver.com/profile/quest.global" target="_blank" rel="noopener noreferrer">Quest Global</a>—a leader with over two decades of experience in digital transformation for aerospace and defense manufacturing—shared actionable strategies to:</p><ul data-spread="false"><li><p><strong>Streamline Design Processes:</strong> Learn how digital twins enable faster design cycles by identifying issues early, verifying interfaces, and simulating real-world conditions.</p></li><li><p><strong>Optimize Manufacturing Methods:</strong> Discover how digital threads support the use of Virtual and Smart Factories to improve production efficiency and enhance collaboration.</p></li><li><p><strong>Enhance Predictive Maintenance:</strong> Understand how real-time data analytics can predict failures, extend equipment lifespan, and optimize operations.</p></li></ul><h3>Expert Insights from Industry Leaders</h3><p><a href="https://www.wevolver.com/profile/nick.charles" target="_blank" rel="noopener noreferrer"><strong>Nick Charles</strong></a><strong>&nbsp;</strong>Head of Engineering - UK Defense, Quest Global<br>With extensive experience leading global engineering teams, Nick shares insights into leveraging digital twin technologies for operational success.</p><p><a href="https://www.wevolver.com/profile/vijay.anand.r" target="_blank" rel="noopener noreferrer"><strong>Vijay Anand R</strong></a><strong>&nbsp;(VJ)&nbsp;</strong>GM – Head of Advanced Manufacturing CoE, Quest Global<br>A veteran in digital manufacturing, Vijay provides practical advice on implementing scalable digital solutions and enhancing manufacturing methods.</p><p><a href="https://www.linkedin.com/in/lukelogan/" target="_blank" rel="noopener noreferrer"><strong>Luke Logan</strong></a><strong>&nbsp;–&nbsp;</strong>Independent advisor and consultant<br>A seasoned business leader with a significant career in engineering and technology and over three decades of senior executive experience, Luke has led global teams and managed major projects at Rolls-Royce plc, BAE Systems plc, and Weir Group plc—three of the world's leading engineering and technology companies. His broad expertise across sectors such as Civil Aerospace, Defence, Power, and Industrial Equipment enables him to share a wealth of insights and foster diversity of thought.</p><h3>Gain insights from successful user cases of digital thread implementation&nbsp;</h3><p>This webinar offers more than just theory. It includes real-world case studies from Quest Global that demonstrate:</p><ul data-spread="false"><li><p>How companies have cut design cycles and improved regulatory compliance.</p></li><li><p>Strategies for creating interoperable systems that reduce costly prototyping.</p></li><li><p>Ways to leverage digital threads for better supply chain integration and decision-making.</p></li></ul><h3>Who Should Watch?</h3><p>If you’re an aerospace engineer, manufacturing professional, or decision-maker seeking to stay competitive and drive innovation, this webinar is for you. Gain the knowledge to:</p><ul data-spread="false"><li><p id="isPasted">Building resilient digital threads to reduce non-conformance in production.</p></li><li><p id="isPasted">Boost productivity through smarter design and manufacturing processes.</p></li><li><p>Position your company as a leader in aerospace and defense innovation.</p></li></ul><h3>Ready to Learn?</h3><p>Don’t miss this opportunity to catch up on the insights and strategies shared during our live event. <strong>Watch the on-demand webinar now</strong> and take the first step toward transforming your operations with digital twin and digital thread technologies:</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:730px;border:none;" scrolling="yes" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><p dir="ltr" id="isPasted">Stay up to date with the latest insights from Quest Global by <a href="https://www.wevolver.com/profile/quest.global">following their company profile.</a></p>

Dive into the future of aerospace manufacturing with our on-demand session.

Listen to industry experts from Quest Global discuss how digital twins are transforming aerospace and defense manufacturing by cutting design cycles, driving predictive maintenance, and improving manufacturing efficiency.

Missed The Webinar? Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing

<p dir="ltr" id="isPasted">Nearly 50% of aerospace and defense companies today report supply chain disruption, impacting production timelines and operational costs. While many executives remain burdened with tedious manual processes for monitoring, data exchange, and management, adopting digital technologies that transform lifecycle management is key to overcoming these disruptions. Here, digital threads technology has emerged as a transformative solution.</p><p dir="ltr">Digital threads offer unprecedented end-to-end connectivity, seamlessly connecting every phase of a product’s lifecycle and ensuring data and insights flow uninterrupted from design to deployment. Integrating Enterprise Architecture (EA), Model-Based Systems Engineering (MBSE), Model-Driven Engineering (MDE), Product Lifecycle Management (PLM), and Advanced Digital Manufacturing into these digital threads can help future-proof aerospace companies against prospective challenges and disruptions. When these methodologies are applied together, they empower companies to streamline processes, adapt to technological advancements, and maintain a competitive edge.</p><h2 dir="ltr">The Growing Importance of Digital Threads in Aerospace Lifecycle Management</h2><p dir="ltr">A digital thread represents a comprehensive, seamless flow of data that links each stage of a product's lifecycle, from concept to final deployment. In aerospace, where products are increasingly complex and involve numerous stakeholders, digital threads are becoming indispensable. They allow for better collaboration, support real-time decision-making, and enhance efficiency by ensuring information consistency across teams.&nbsp;</p><p dir="ltr">Today, a quarter of the PLM market is attributed to the aerospace industry, showing a solid promise toward an increase in embracing agile PLM solutions. As aerospace companies manage more sophisticated supply chains and stringent regulatory requirements, the need for such a cohesive approach to digital manufacturing has never been more pressing.</p><p dir="ltr">Digital manufacturing is rapidly becoming a key differentiator in aerospace operations. Rather than a passing trend, it is an essential component of Industry 4.0 strategies as aerospace suppliers and OEMs seek to leverage its potential. By integrating such digital solutions, these companies can enhance their agility and resilience, positioning themselves to meet the demands of an evolving global industry. This shift is reshaping traditional manufacturing processes, allowing aerospace manufacturers to unlock greater value through improved connectivity, efficiency, and adaptability.</p><h1 id="isPasted">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h1><p dir="ltr">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr">The Strategic Role of Enterprise Architecture (EA) in Governance</h2><p dir="ltr">Global competition today is driving aerospace companies to increase productivity and efficiency swiftly, ensuring digital frameworks are both advanced and strategically aligned. Underlying these digital frameworks is Enterprise Architecture (EA), a blueprint that characterizes a company’s structure and operation.</p><p dir="ltr">EA is the backbone of a resilient digital thread, enabling alignment between the company’s strategic objectives and the technical architectures in place. It serves as a governance framework that helps enforce compliance, security, and adherence to industry standards, thereby ensuring that digital threads are built in a controlled and strategic manner. This alignment ensures that digital transformation initiatives do not stray from organizational goals, providing a structured approach to lifecycle management.</p><p dir="ltr">Importantly, EA establishes the foundation upon which tools like MBSE operate. While EA connects technological solutions with broader business objectives, MBSE focuses on the technical implementation of those solutions within the product development lifecycle. Without the governance and strategic alignment provided by EA, MBSE’s capabilities cannot be effectively harnessed. Conversely, MBSE brings EA’s strategic vision to life by enabling precise, actionable insights through detailed models.</p><p dir="ltr">EA is essential in connecting technological solutions with broader business objectives, preventing the creation of operational silos. By bridging gaps between engineering, production, and business units, EA ensures the digital thread remains unified, supporting consistent data flow and collaboration across the organization.</p><p dir="ltr">By bridging gaps between engineering, production, and business units, EA ensures that digital threads remain unified, preventing operational silos. When paired with MBSE, they support a seamless flow of data and insights across the organization, forming a cohesive framework that optimizes lifecycle management and aligns every aspect of the product’s journey with organizational objectives.</p><h3 dir="ltr">Enhancing Lifecycle Management through MBSE and MDE</h3><p dir="ltr">To fully realize the potential of digital threads, aerospace companies need tools like MBSE and MDE that enhance lifecycle resilience and data consistency, providing critical frameworks for improving the reliability and efficiency of digital threads.</p><p dir="ltr">MBSE offers a system-centric approach to managing the product development lifecycle. By creating precise, detailed models, MBSE ensures that teams can collaborate effectively, sharing a common understanding of the project’s status and critically creating one configured, traceable, and controlled version of the design. This enhanced clarity reduces the risk of miscommunication and design errors.&nbsp;</p><p dir="ltr">One example is Quest Global's collaboration with a leading aeronautics OEM to support advanced-generation military products with MBSE integration. Using MBSE, Quest Global effectively built a comprehensive architecture, conducted model building, and managed requirements decomposition. This approach enabled the team to create a detailed system-level view, significantly reducing design errors and enhancing collaboration. As a result, Quest Global helped the OEM achieve better decision-making and smoother project execution.</p><p dir="ltr">Building on the system-centric foundation established by MBSE, MDE introduces automation and efficiency to streamline processes further. It automates repetitive tasks and processes, thereby reducing human error and accelerating development timelines. This automation is especially valuable in maintaining data integrity across different project phases, from design to manufacturing and beyond. Combining automated workflows and consistent data flow ensures no critical information is lost during handovers between teams, leading to improvements in Right First Time (RTF) outcomes.</p><p dir="ltr">The synergy of EA’s strategic alignment, MBSE’s system thinking, and MDE’s automation tools in digital threads fosters a collaborative workflow that supports data integrity, optimized project timelines, and enhanced decision-making with accurate, real-time information.</p><h2 dir="ltr">Cybersecurity Considerations for Resilient Digital Threads</h2><p dir="ltr">While digital threads offer significant advantages, their interconnected nature can introduce vulnerabilities at different stages between design and operational deployment. In aerospace, these cyber threats can have far-reaching consequences, including data breaches, intellectual property theft, and compromised system integrity, potentially jeopardizing entire projects. As digital threads link sensitive design data with manufacturing and operational environments, it’s essential to mitigate these cybersecurity risks effectively.</p><p dir="ltr">Implementing robust encryption protocols is crucial to securing digital threads, ensuring that sensitive data remains protected throughout each phase of its lifecycle. Encryption guards against unauthorized access by making data unreadable without the appropriate keys, reducing the risk of interception during data transmission or storage. In addition, role-based access controls (RBAC) ensure that only authorized personnel can access specific parts of the digital thread, minimizing internal vulnerabilities.&nbsp;</p><p dir="ltr">Multi-factor authentication (MFA) adds another layer of defense, requiring multiple forms of verification before granting access, which makes unauthorized entry far more challenging. Similarly, continuous monitoring systems play a vital role by providing real-time threat detection and response capabilities, allowing organizations to quickly identify and mitigate potential security breaches before they escalate. Together, these measures create a multi-layered defense strategy that protects the integrity and confidentiality of data across the digital thread. This ensures the digital thread remains resilient against external attacks and internal vulnerabilities.</p><p dir="ltr">By integrating cybersecurity measures directly into digital threads, aerospace firms can enhance security from the initial design phase, embedding protective protocols into every step of product development. This proactive approach reduces vulnerabilities and ensures that security is foundational rather than an afterthought. EA strengthens this approach by defining comprehensive security policies and enforcing them across the entire product lifecycle, thus creating a cohesive and exercisable framework that all stakeholders must follow. Complementing EA, tools like MBSE and MDE ensure consistency and traceability of data, while PLM and Enterprise Resource Planning (ERP) systems streamline operations and enable efficient data management. Together, these tools maintain the integrity of digital threads, reducing risks and ensuring robust protection throughout the lifecycle.</p><h2 dir="ltr">Long-Term Benefits of a Resilient Digital Thread</h2><p dir="ltr">A robust digital thread equips aerospace companies with the adaptability needed to respond to emerging technologies and market demands. Its scalability supports growth and innovation, ensuring that companies can continuously improve. By building resilient digital threads, organizations can optimize current operations, reduce product development lead time, reduce rework, and establish a solid foundation for future success, gaining a competitive advantage over those with fragmented systems.</p><p dir="ltr">Incorporating EA, MBSE, MDE, and cybersecurity practices into digital thread strategies enables aerospace companies to build a resilient, future-ready framework. Therefore, forward-thinking aerospace companies can optimize today’s operations by investing in comprehensive and secure digital threads while preparing for tomorrow’s challenges.&nbsp;</p><p dir="ltr">Interested in implementing resilient digital threads? Quest Global can be your strategic partner in navigating this transformation. With over two decades of experience in digital manufacturing, Quest Global provides turnkey solutions for aerospace manufacturing that support product lifecycle management, enabling OEMs to transform their business as the aerospace industry increasingly adopts Industry 4.0.</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p>

How digital threads enhance lifecycle resilience, ensuring seamless data flow, robust cybersecurity, and adaptability to tackle supply chain disruptions and evolving aerospace challenges.

Connecting the Dots: Building Resilient Digital Threads for Aerospace Lifecycle Management

<p dir="ltr" id="isPasted">The aerospace industry faces mounting pressures as systems grow increasingly complex while demands intensify for reduced cycle times and lower costs. To stay competitive, companies must adopt faster, more efficient design processes that can keep pace with these developing challenges. However, traditional approaches often struggle to deliver the required speed and accuracy.</p><p dir="ltr">Digital solutions, such as parametric modeling and optimization tools, are essential in this context as they enable engineers to create flexible and adaptive designs that can quickly accommodate changes and improve performance. These tools allow for rapid iteration and analysis of various design scenarios, enhancing decision-making and efficiency, ultimately streamlining the entire development process in an industry where precision and speed are critical.</p><p dir="ltr">Quest Global is a leader in digital thread integration and model-based systems engineering (MBSE). It provides tools and consultative services to assist companies in using a model-based approach. In the following sections, we'll explore how Quest Global's parametric modeling and automation tools can reduce design cycle times, improve accuracy, and accelerate the evaluation of critical aerospace systems.</p><h2 id="isPasted">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h2><p dir="ltr">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr">Understanding Parametric Modeling in Aerospace Manufacturing</h2><p dir="ltr">Parametric modeling is a design approach that defines a component using parameters such as dimensions, shapes, and constraints. This automatically updates the model geometry whenever these parameters are modified, allowing for rapid and consistent iterations.[1]&nbsp;By establishing connections between different parts of the model, parametric modeling enables designers to create complex and adaptable designs.</p><h3 dir="ltr">Key Features of Parametric Modeling</h3><p dir="ltr">One of the primary advantages of parametric modeling is its ability to automate repetitive tasks. Engineers can quickly update designs by changing parameters without recreating the entire model from scratch. This greatly accelerates the design process and allows for more efficient exploration of design alternatives. Moreover, parametric models are data-driven, meaning they rely on input data to generate optimized designs that minimize errors and improve performance.[2]</p><p dir="ltr">Several well-known parametric design software packages are widely used in the aerospace industry, such as Dassault Systèmes' CATIA, Siemens NX, PTC Creo, and Autodesk Inventor. These tools provide extended features for creating, analyzing, and optimizing aerospace components and systems. They also streamline the design process and facilitate collaboration between teams.</p><h3 dir="ltr">The Role of Parametric Modeling in Aerospace</h3><p dir="ltr">In the aerospace industry, parametric modeling plays an important role in designing engines and airframes. These systems must meet stringent performance criteria, and parametric modeling provides the precise control needed to ensure accurate outputs. For instance, when designing complex parts such as rotors and casings, parametric modeling enables engineers to rapidly iterate on different configurations and assess their impact on overall performance.[3]&nbsp;</p><p dir="ltr">Furthermore, this integrates with broader digital engineering tools, creating a connected digital thread that spans the entire product lifecycle. This connectivity allows traceability and changes to propagate throughout the design and manufacturing processes, ensuring consistency and reducing the risk of errors.</p><h2 dir="ltr">Key Benefits of Parametric Modeling in Aerospace Design</h2><p dir="ltr">The aerospace industry was one of the first to fully adopt parametric modeling, which&nbsp;has yielded numerous benefits. One of the most significant advantages is the faster design cycles. Engineers make real-time updates to their designs, which reduces the time required for each iteration. This capability allows for rapid exploration of design alternatives and enables teams to converge on an optimized solution much faster than traditional methods.</p><p dir="ltr">In addition to speed, parametric modeling also improves accuracy and precision throughout the design process. Automated processes and built-in constraints help minimize the risk of errors, assuring that models maintain a high degree of fidelity from concept to production.[4]&nbsp;This improved accuracy enables faster design verification, as virtual simulations can be conducted more confidently, hence reducing the need for physical prototypes.</p><h3 dir="ltr">Enhancing Cross-functional Collaboration and Flexibility in Design</h3><p dir="ltr">Parametric modeling boosts cross-functional collaboration. The integration of design and analysis tools within a parametric framework enables communication between teams, allowing engineers from different disciplines to collaborate more effectively. This helps identify potential issues early in the design process when they are less costly to address.</p><p dir="ltr">Another benefit is the flexibility it provides in the face of changing requirements. By updating values assigned to design parameters, engineers can accommodate new specifications without significant disruption to their workflows. This agility is particularly valuable in the aerospace industry as design changes are expected due to shifting customer needs or regulatory requirements.</p><h3 dir="ltr">Improving Cost Efficiency and Optimizing Resources</h3><p dir="ltr">Parametric modeling helps optimize resource utilization and reduce costs. By improving digital models, companies can minimize the need for expensive and time-consuming physical prototypes and testing. This reduction in physical resources allows for more efficient allocation of budget and personnel, ultimately leading to cost savings and faster time to market for new products.</p><h2 dir="ltr">Digital Design Case Study: Parametric Modeling and Optimization</h2><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyNTM5NTE5MjY1LXNodXR0ZXJzdG9ja18yMjQwNzk1NDkzLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr">We know that efficiency and innovation are paramount in aerospace manufacturing. This case study highlights the collaboration between Quest Global and a leading aero-engine manufacturer. Quest Global's expertise in parametric modeling and automation tools improved the manufacturer's design processes.</p><p dir="ltr">The aero-engine manufacturer faced a significant hurdle in their design workflow. They aimed to substantially reduce the cycle time from conceptual design to optimized 3D models. To achieve this, they required a solution capable of utilizing meanline profiles from aerothermodynamic analyses, building conceptual rotor with aerofoil and casing models to efficiently explore the design space. Their existing methods required considerable engineer efforts and struggled to meet schedule demands. And hindered their ability to explore the design space required to achieve optimal rotor and casing designs.</p><h3 dir="ltr">Comprehensive Design Transformation through Automation and Standardization</h3><p dir="ltr">Recognizing the need for a comprehensive solution, the aero-engine manufacturer partnered with Quest Global. Quest Global deployed a dedicated team of 12 skilled engineers to support the manufacturer's future engine program. This specialized team worked closely with the manufacturer's engineers to understand their specific requirements and develop tailored strategies to facilitate their design processes.</p><p dir="ltr">Quest Global's approach centered on the development of standardized design methods and the implementation of advanced automation tools. By introducing automated geometry tagging and cross-section automation, they significantly reduced the manual effort required in the design process. Additionally, the utilization of Siemens NX parametric modeling tools enabled rapid iterations and integration of design updates, allowing engineers to explore a broader range of design options in a fraction of the time previously required.</p><h3 dir="ltr">Reducing Human Error in Design: Quest Global’s Automation Edge</h3><p dir="ltr">One of Quest Global's key differentiators was the implementation of automated meshing and boundary condition generation for gas turbine engine design. This eliminated the potential for human error and provided consistent, high-quality results. Moreover, their verification systems, built upon robust simulation frameworks, gave engineers the confidence to make data-driven decisions and optimize designs based on reliable performance predictions.</p><p dir="ltr">Perhaps most importantly, Quest Global focused on establishing strong connectivity between design processes and tools that facilitated automation and collaboration—Quest Global integrated parametric modeling with the manufacturer's existing design ecosystem.</p><p dir="ltr">The impact of the partnership with the aero-engine manufacturer was significant. The manufacturer achieved a remarkable 30% reduction in design cycle time by implementing parametric modeling and optimization tools. This allowed them to bring engine designs to market faster, gaining a competitive edge in the industry. Additionally, the improved design accuracy and the ability to rapidly evaluate complex system components contributed to enhanced product performance and reliability.</p><h2 dir="ltr">Leveraging Digital solutions for Aerospace manufacturing</h2><p dir="ltr">Quest Global's expertise extends beyond parametric modeling to digital twin technology. Integrating digital twins with parametric modeling makes it easy to gain insight and control over aerospace manufacturing processes. Digital twins are virtual replicas of physical systems, capturing real-time data and enabling engineers to monitor, analyze and optimize performance throughout the product lifecycle.</p><p dir="ltr">The synergy between digital twins and parametric modeling provides predictive capabilities for aerospace manufacturers. Engineers can anticipate potential issues, identify opportunities for improvement, and make informed decisions based on accurate, up-to-date information. This allows for implementing adaptive manufacturing processes, where production lines can dynamically adjust to changing conditions and minimize downtime.[5] Quest Global's expertise in this domain enables aerospace companies to lead in innovation, produce high-quality products, and continuously improve their processes.</p><h2 dir="ltr">References</h2><ol><li dir="ltr"><p dir="ltr">Monedero J. Parametric design: a review and some experiences. Automation in construction. 2000 Jul 1;9(4):369-77.</p></li><li dir="ltr"><p dir="ltr">Schulze M, Neumann J, Klimmek T. Parametric modeling of a long-range aircraft under consideration of engine-wing integration. Aerospace. 2020 Dec 23;8(1):2.</p></li><li dir="ltr"><p dir="ltr">Li W, Krist S, Campbell R. Transonic airfoil shape optimization in preliminary design environment. Journal of aircraft. 2006 May;43(3):639-51.</p></li><li dir="ltr"><p dir="ltr">Shi R, Long T, Ye N, Wu Y, Wei Z, Liu Z. Metamodel-based multidisciplinary design optimization methods for aerospace system. Astrodynamics. 2021 Sep;5:185-215.</p></li><li dir="ltr"><p dir="ltr">Sanchez F, Liscouët-Hanke S, Tfaily A. Improving aircraft conceptual design through parametric CAD modellers–a case study for thermal analysis of aircraft systems. Computers in Industry. 2021 Sep 1;130:103467.</p></li></ol>

Discover how parametric modeling enables faster iterations, improved accuracy, and optimized aerospace design and manufacturing performance.

Accelerating Aerospace Design with Parametric Modeling and Optimization

<p dir="ltr" id="isPasted">Aerospace and defense (A&amp;D) manufacturing operates in one of the most regulated and complex environments, where precision, compliance, and safety are non-negotiable. Every component, from aircraft parts to defense systems, must meet rigorous standards, and a single defect can lead to costly rework, delayed timelines, and compliance failures that compromise safety. Despite advancements in manufacturing, non-conformance remains a pervasive challenge that disrupts production and drives up costs. Frequent quality issues, often stemming from the limitations of traditional methods and disconnected systems, have ripple effects throughout the supply chain, creating risks and eroding operational efficiency as production scales and becomes increasingly globalized.</p><p dir="ltr">Digital threads offer a transformative solution to these challenges. By creating an interconnected data flow that spans the entire product lifecycle, digital threads enable real-time quality control and predictive insights that empower manufacturers to detect, address, and even prevent non-conformances before they escalate. Quest Global is pioneering digital thread technology in A&amp;D manufacturing by integrating Model-Based Enterprise &nbsp;(MBE), digital twins, and predictive maintenance. Its approach targets zero defects and redefines quality management as a proactive, data-driven strategy that delivers unprecedented levels of control, reliability, and efficiency across the industry.</p><h2 dir="ltr">Quest Global’s Vision for Zero Defects in A&amp;D Manufacturing</h2><p dir="ltr">Quest Global combines cutting-edge technologies and industry-proven methodologies to set a new benchmark for precision in A&amp;D manufacturing. Their approach embeds continuous data flows and real-time feedback loops into production, enabling manufacturers to maintain rigorous quality standards without sacrificing speed or flexibility.</p><p dir="ltr">At the core of Quest Global’s strategy is the digital thread, a cohesive system that unites design, manufacturing, and maintenance processes into a single, continuous data stream. This interconnected framework addresses non-conformance by embedding real-time traceability and compliance verification directly into the manufacturing workflow, transforming quality management from a series of isolated checks into an integrated process. Through structured methodologies such as Root Cause Corrective Action (RCCA) and the 8D process, Quest Global systematically addresses quality issues at their source, preventing recurrence and ensuring comprehensive compliance.&nbsp;</p><p dir="ltr">This application of digital threads allows A&amp;D manufacturers to identify and resolve quality issues proactively, building a foundation of precision and consistency across global supply chains. By bridging the gaps between design, manufacturing, and maintenance, digital threads provide a comprehensive view of the product lifecycle, facilitating a proactive approach to tackling non-conformance.</p><h2 dir="ltr">Digital Solutions Transforming A&amp;D Manufacturing</h2><p dir="ltr">Quest Global’s digital thread strategy is built on foundational technologies that address the complexities and precision demands of A&amp;D manufacturing. MBE is central to this approach, allowing engineers to create, test, and continuously update dynamic models. It enables real-time adjustments and validation throughout the design phase, which helps maintain precision and minimize the risk of errors that could cascade through the production process. Enhanced by parametric modeling, MBE provides flexibility in testing and refining designs well before they reach production, effectively reducing the likelihood of non-conformance issues at their earliest stages.</p><p dir="ltr">Digital twins complement MBE by bridging the gap between virtual design and physical production. Acting as real-time digital replicas of physical assets, digital twins provide a continuous, data-rich view of equipment performance and conditions. For A&amp;D manufacturers, this means instant insight into how assets behave under specific conditions, helping them identify and correct potential quality issues before they impact the final product.&nbsp;</p><p dir="ltr">When coupled with predictive maintenance, digital twins go beyond monitoring by forecasting maintenance needs based on real-time data. Through advanced analytics and machine learning, digital twins enable manufacturers to anticipate failures, optimize equipment uptime, and prevent costly interruptions or defects in production.</p><p dir="ltr">Digital threads unify these core technologies into a single, interconnected data flow that spans the product lifecycle from design to manufacturing to aftermarket . This integration creates a “single source of truth” for all production data, allowing every team involved in the manufacturing process to work from the same, continuously updated information.&nbsp;</p><p dir="ltr">As a result, it facilitates traceability and enforces consistency, ensuring quality standards are upheld at every stage. Any deviation from the design or production process is instantly visible, enabling swift corrective actions that uphold compliance and minimize costly rework. By embedding these digital solutions within the production workflow, Quest Global empowers A&amp;D manufacturers to achieve precision, enhance operational resilience, and build a robust, data-driven foundation for addressing non-conformance issues on a global scale.</p><h2 dir="ltr">Real-World Applications: The Benefits of Digital Threads in A&amp;D</h2><p dir="ltr">Traditional A&amp;D manufacturing has historically relied on manual inspections and outdated systems that struggle to keep pace with modern complexity. Quest Global’s digital thread approach replaces these inefficiencies with an automated, interconnected solution. This shift from reactive to proactive quality management empowers manufacturers to pinpoint potential issues long before they manifest, dramatically reducing the need for rework and ensuring high compliance rates.</p><h3 dir="ltr">Case Study: Streamlined Production Support for Aerospace Manufacturing</h3><p dir="ltr">An aerospace client sought to revamp their producibility flow line to improve efficiency and reduce non-conformance. Quest Global established a dedicated cross-functional team, to manage the overall operations and flowlines. Through data visualization tools, , Quest Global enabled real-time tracking of KPIs &nbsp;that helped identify and eliminate bottlenecks methodically.&nbsp;</p><p dir="ltr">This structured approach allowed for proactive root cause analysis, enabling effective trend analysis and forecasting of quality issues. Quest Global’s solutions achieved a 30% reduction in non-conformance on key products and a 65% reduction in backlog. Further, Quest Global enhanced the client’s real-time monitoring capabilities with a whiteboard-to-digital transformation, improving the quality of Non Conformance origination data by greater than 95% &nbsp;and total resolution time (TRT) within one day, leading to improved quality and efficiency across the production process.</p><h3 dir="ltr">Case Study: Predictive Quality Management with Data-Driven Insights</h3><p dir="ltr">Another aerospace manufacturer faced high costs of poor quality (CoPQ) and frequent production delays due to inconsistent quality management across a globally distributed supply chain. To address these challenges, Quest Global implemented a predictive quality management solution that combined DMAIC methodology, real-time data analytics, and machine learning.&nbsp;</p><p dir="ltr">This solution utilized correlation and regression analysis to build relation of process variables . By streamlining non-conformance management and enhancing the client’s ability to forecast issues, Quest Global reduced non-conformance rates by 28% and improved TRT by 50%, leading to $2.4 million in annual savings. Additionally, the solution helped improve productivity by 22% significantly enhancing overall production reliability.</p><p dir="ltr">These case studies highlight how Quest Global empowers manufacturers to reduce non-conformance, streamline production, and achieve substantial cost savings, setting a new standard for operational efficiency and reliability in the industry.</p><h2 dir="ltr">Pioneering a Digital-First Future in Aerospace Manufacturing</h2><p dir="ltr">Quest Global envisions a future where digital threads, automation, and AI-driven systems become fundamental to A&amp;D manufacturing. By transforming quality management into a strategic advantage, Quest Global’s digital solutions empower manufacturers to uphold rigorous standards without compromising efficiency.</p><p dir="ltr">This seamless, digital-first approach positions quality control as a competitive differentiator, enabling A&amp;D manufacturers to proactively address challenges, optimize production, and ensure consistent compliance throughout the supply chain. By unifying each phase of production within a data-centric framework, Quest Global’s digital thread solutions reduce non-conformance, improve transparency, and integrate predictive insights that strengthen operational resilience and overall efficiency.</p>

Aerospace and defense manufacturing faces strict quality demands where non-conformance disrupts efficiency. Read how Quest Global is leading the transformation to a more proactive, data-driven approach that delivers unprecedented levels of control, reliability, and efficiency across the industry.

Leveraging Digital Threads to Minimize Non-Conformance in A&D Manufacturing

<p dir="ltr" id="isPasted">As aerospace and defense manufacturing targets higher precision and efficiency, digital twin and digital thread technologies are quietly reshaping how products move from design to the real world. These advancements enable companies to bridge the gap between design and production, driving down cycle times while improving innovation, safety, and adaptability. With the aerospace and defense (A&amp;D) sector transitioning to digital-first methodologies, the need for seamless integration of these technologies has never been more critical.</p><p dir="ltr">A&amp;D manufacturers today must meet tighter production schedules, ensure greater accuracy, and create systems that can evolve in real time to changing conditions. Digital twins and digital threads serve as a single source of truth, ensuring interoperability across the lifecycle of each asset—from requirements capture to assembly and certification. In this context, these technologies are pulling the strings to improve operational efficiency and deliver data-driven insights. Companies that embrace these tools are positioning themselves to lead the next generation of A&amp;D engineering.</p><h2 dir="ltr" data-element-id="headingsMap-4-0">Digital Twin and Digital Thread in Aerospace and Defense</h2><p dir="ltr">The A&amp;D sector stands to benefit greatly from innovations like digital twins and digital threads, especially with its demand for precision and safety. As&nbsp;A&amp;D products&nbsp;shifts towards mechatronics, digital twins allow system integration across mechanical, electronic, and software components, capturing real-time data to provide actionable insights into performance and condition. This helps implement&nbsp;smart manufacturing,&nbsp;remote asset monitoring,&nbsp;robust configuration &amp; traceability, predictive maintenance, reducing unplanned downtime and extending equipment lifespan.</p><p dir="ltr">Model-Based Systems Engineering (MBSE) frameworks combined with digital threads help to standardize workflows from CAD/CAE to CAM/CMM, supporting both new product introduction and industrialization. In defense, digital twins allow for real-time operational readiness assessments of critical assets like fighter jets, naval vessels, and unmanned systems, while digital threads ensure system integrity and a continuous data flow across the entire lifecycle—from mission planning to post-deployment sustainment.</p><p dir="ltr">These technologies are applicable across multiple domains—land, air, maritime, and space—to optimize design, improve maintenance, and ensure peak performance in all environments. They also support the global nature of defense contracts, with embedded Product Manufacturing Information (PMI) and annotations overcoming language barriers in multinational operations.</p><p dir="ltr">As companies look to optimize performance and reduce cycle times, adopting these technologies is helping them achieve significant operational improvements, thus creating more cohesive, data-driven systems for better decision-making and long-term sustainability.</p><h2 id="isPasted" data-element-id="headingsMap-5-0">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h2><p dir="ltr">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr" data-element-id="headingsMap-7-0">Industry Insights: Driving Innovation through Digital Integration</h2><p dir="ltr">Quest Global has worked across various A&amp;D projects, helping companies integrate digital thread strategies to accelerate timelines and enhance efficiency. In the defense space, this integration enables complex systems, such as military aircraft and missile defense platforms, to move seamlessly from concept to deployment while maintaining mission-critical performance and security. By digitizing Standard Operating Procedures (SoPs) and augmenting them with simulations through Virtual Reality (VR) and Augmented Reality (AR), digital twins streamline production and enable maintenance, repair, and overhaul (MRO) with enhanced accuracy.</p><p dir="ltr">In a project with a leading aeroengine OEM for the US Department of Defense (DoD), Quest Global’s design thread expertise, particularly in MBSE, was critical in connecting systems architecture and accelerating the design process. In another project, they helped reduce manufacturing design cycle times by 30% using adaptive closed-loop manufacturing, predictive analytics, and supply chain connectivity. This digital twin initiative improved the overall efficiency by 44%, demonstrating the power of real-time simulations and predictive analytics in reducing non-conformance and optimizing manufacturing.</p><h2 dir="ltr" data-element-id="headingsMap-8-0">The Industry-Wide Impact of Digital Twin and Digital Thread Technologies</h2><p dir="ltr">Digital twins and digital threads enable companies to create continuous, data-driven feedback loops that enhance decision-making, streamline operations, and reduce inefficiencies and complexities. By embedding real-time insights into their processes, A&amp;D manufacturers can optimize performance at every stage of the product lifecycle, from design to production and maintenance.</p><p dir="ltr">Digital twins, in particular, allow manufacturers to simulate different scenarios and test outcomes without needing physical prototypes. This helps reduce risk, accelerate time-to-market, and improve overall system reliability. With digital twins, we’re seeing a shift from reactive to proactive management in aerospace manufacturing. It goes beyond preventing failures toward continuously improving processes, shortening design cycles, and enabling adaptive manufacturing that responds in real time to operational data.</p><p dir="ltr">Meanwhile, digital threads ensure that data remains connected and accessible throughout the entire lifecycle, bridging gaps between traditionally siloed systems. This interconnectedness fosters collaboration and allows for more informed decision-making, helping companies meet the growing demands for efficiency, sustainability, and speed. In A&amp;D, real-time data integration supports faster response times and optimizes product performance under changing geopolitical scenarios, empowering&nbsp;OEM’s &amp; Global Supply chain&nbsp;to maintain readiness in dynamic environments.&nbsp;Digital manufacturing and Industry 4.0 technologies also foster increased awareness and improvement toward Health and Social care (HSC).</p><p dir="ltr">As the A&amp;D industry embraces digital technologies, manufacturers are empowered to optimize their operations and properly position themselves to innovate and adapt to future challenges, laying the groundwork for smarter, more responsive manufacturing ecosystems.</p>

Bridging Design and Production: Why Digital Twin and Thread Are Vital for Aerospace Innovation

Harnessing the Power of Digital Twins for Seamless Digital Thread Integration

<p dir="ltr" id="isPasted">As aerospace and defense projects grow in complexity, the industry faces a need for new methodologies to manage complex system architectures and facilitate design validation processes. Model-Based Systems Engineering (MBSE) is addressing these challenges by moving organizations from document-based systems to a model-centric approach.&nbsp;</p><p dir="ltr">One key player driving this transformation is Quest Global, a leading engineering services provider renowned for its pioneering role in digital thread integration across the aerospace and defense industry. Quest Global has established itself as a trusted partner, helping major aerospace organizations adopt Model-Based Systems Engineering (MBSE) and leverage digital thread solutions to enhance project efficiency, system accuracy, and cross-functional collaboration. Their expertise in integrating MBSE techniques has enabled aerospace companies to meet modern challenges head-on, significantly improving project outcomes.</p><p dir="ltr">This article explores how MBSE connects design processes and tools to enable greater flexibility, accuracy, and efficiency in aerospace and defense projects. It also highlights Quest Global's role in leading this transformation, providing case studies on successful implementation to illustrate its real-world applications and benefits across all development stages.</p><h2 dir="ltr" data-element-id="headingsMap-4-0">Why the Shift from Document-Based to Model-Based Systems Engineering?</h2><p dir="ltr">MBSE is a systems engineering methodology that fundamentally improves how complex systems are developed and managed throughout their entire lifecycle. At its core, MBSE allows for an authoritative source of truth (ASoT) for systems, depicting components as interconnected blocks with defined boundaries and interfaces. This visual representation aids both technical and non-technical stakeholders in understanding complex systems. For example, in developing a new turbofan engine, MBSE can map interactions between the engine and external systems like avionics and flight controls.</p><p dir="ltr">One of the key features of MBSE is its centralized model-based approach. In MBSE, a well-structured model provides a graphical representation of processes, structures, and workflows, making it easier to understand and manage. In this approach, changes made within a model propagate automatically, ensuring consistency and reducing labor.</p><h2 id="isPasted" data-element-id="headingsMap-5-0">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h2><p dir="ltr" id="isPasted">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr" data-element-id="headingsMap-7-0">Benefits of MBSE in Aerospace</h2><p dir="ltr">Model-Based Systems Engineering (MBSE) significantly enhances efficiency by streamlining the development process, leading to reduced time to market and faster product launches. This approach also contributes to substantial cost reductions by leveraging models effectively to identify and address inefficiencies early in the development cycle.</p><p dir="ltr">A core objective of MBSE is to improve product quality by enhancing system design and reducing defects. Executives can monitor this improvement through key metrics, such as defect rates and performance indicators, reflecting the quality of systems engineering outputs. Additionally, MBSE fosters stakeholder satisfaction through improved communication and collaboration across teams.&nbsp;</p><p dir="ltr">Assessing the return on investment (ROI) of MBSE is crucial for understanding its financial impact. Executives should evaluate cost savings from reduced errors, increased productivity from streamlined processes, and improved product quality that leads to better market performance. Furthermore, it is essential for MBSE initiatives to align with the organization’s strategic goals. Evaluating the extent to which MBSE contributes to long-term success ensures that it serves as a strategic enabler, supporting the organization's vision and mission.</p><h2 dir="ltr" data-element-id="headingsMap-8-0">From Complexity to Clarity: Streamlining Aerospace Design with MBSE</h2><p dir="ltr">The use of a digital modeling approach significantly enhances system architecture in aerospace projects, offering improved visualization and analysis. Digital models provide a clear and cohesive representation of complex systems, enabling engineering teams to better understand and navigate the intricacies of the design architecture.</p><p dir="ltr">Quest Defense (QDSS), the US subsidiary of Quest Global, has been instrumental in helping its clients navigate the complexities of MBSE implementation. Recent projects have demonstrated Quest Defense's capability to streamline systems engineering processes and deliver tangible ROI for its clients.</p><p dir="ltr">A prime example of this is the F-35 program, in which QDSS was a key partner. Despite its success, the F-35 program initially faced numerous challenges, including significant budget overruns and delays. Some of the key challenges included maintaining and evolving unified systems engineering artifacts, traceability, communications, incomplete validation and verification requirements, as well as not reusing systems developed in earlier programs.&nbsp;</p><p dir="ltr">Learning from past challenges, the Department of Defense (DOD) has issued a mandate to build a systems engineering infrastructure using MBSE to address the shortcomings of classical systems engineering methods. MBSE artifacts serve as the Authoritative Source of Truth (ASoT), ensuring consistency throughout the program, reducing the risk of systems architecture divergence, better documenting V&amp;V requirements, and improving communication. Additionally, MBSE facilitates the creation of reusable models for future development, borrowing principles from object-oriented software design. The F-35 was therefore developed as an entirely bespoke effort, with everything built from the ground up. This approach highlighted the need for a more efficient system. This approach allowed for the incorporation of reusable components into new projects, thereby decreasing development time, costs, and risks.</p><p dir="ltr">With QDSS’ support, the Original Equipment Manufacturer (OEM) experienced accelerated project timelines, significant reductions in design and development costs, and improved system strategies and architectures. QDSS’ digital thread integration enabled a streamlined flow of data across the entire development process, enhancing system traceability and ensuring real-time updates in response to design changes.</p><h2 dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMwMjkxNDM5Njg3LXNodXR0ZXJzdG9ja18yMjQwNzk1NTQxLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></h2><h2 dir="ltr" data-element-id="headingsMap-10-0">MBSE’s Strategic Edge in Aerospace and Defense Engineering</h2><p dir="ltr">The success of the F-35 program highlights the many benefits of adopting a MBSE approach for aerospace and defense manufacturing. Some other key advantages include:&nbsp;</p><ul><li dir="ltr"><p dir="ltr"><strong>Enhanced Traceability and Consistency:</strong> MBSE ensures that all changes are automatically updated throughout the system, maintaining consistency and reducing manual effort.</p></li><li dir="ltr"><p dir="ltr"><strong>Improved Communication:</strong> The graphical nature of MBSE models facilitates better communication among stakeholders, including non-technical personnel, by providing clear visualizations of system interactions.</p></li><li dir="ltr"><p dir="ltr"><strong>Reuse of Models:</strong> Models can be stored in libraries and reused in future projects, significantly reducing development time and costs. This is particularly beneficial in A&amp;D, where similar components like turbines or engines can be repurposed with minimal modifications.</p></li><li dir="ltr"><p dir="ltr"><strong>Reduced Risk of Overruns</strong>:&nbsp;MBSE provides a clear and consistent roadmap that mitigates risks associated with budget overruns and project delays.</p></li><li dir="ltr"><p dir="ltr"><strong>Seamless Independent Validation and Verification:</strong> Independent Validation &amp; Verification (IV&amp;V) is critical to any systems engineering process. Validation ensures that the correct system is being built according to requirements (validating against the CONOPS), while Verification ensures that the system is being built correctly (meeting the requirements). MBSE supports IV&amp;V by mapping these cases both graphically and tabularly, creating clear linkages between requirements, validation, and verification. This reduces errors and simplifies the verification process to ensure the system works and that test cases are included in the model.</p></li></ul><h2 dir="ltr" data-element-id="headingsMap-11-0">Addressing MBSE Implementation Issues</h2><p dir="ltr">Transitioning to MBSE is not without its challenges. Organizations often face resistance due to the significant paradigm shift required. Key challenges include:&nbsp;</p><ul><li dir="ltr"><p dir="ltr"><strong>Organizational Buy-In:</strong> Senior management must be convinced of MBSE's benefits, necessitating a top-down approach to implementation.</p></li><li dir="ltr"><p dir="ltr"><strong>Training and Education</strong>:&nbsp;Employees need to learn a new vocabulary and syntax, transitioning from text-based documentation to graphical models. Comprehensive training is essential to facilitate this shift.</p></li><li dir="ltr"><p dir="ltr"><strong>Infrastructure and Tools:</strong> Implementing MBSE requires substantial investment in tools and IT infrastructure. Tools like Cameo can be expensive, and setting up the necessary back-end support involves additional costs.</p></li><li dir="ltr"><p dir="ltr"><strong>Cultural Resistance:</strong> There is often resistance from experienced personnel accustomed to traditional methods. Younger employees may adapt more readily, but older staff may see little value in changing established practices.</p></li></ul><h2 dir="ltr" data-element-id="headingsMap-12-0">Navigating MBSE Hurdles in Complex Engineering Projects</h2><p dir="ltr">In order to ensure a successful MBSE implementation, A&amp;D organizations can take several steps and consult partners like Quest Global to facilitate a smooth transition through the following strategies:</p><ul><li dir="ltr"><p dir="ltr"><strong>Develop Systems Engineering Fundamentals:</strong> Establishing a solid systems engineering process is crucial before transitioning to MBSE. This includes developing a requirements definition and management process, configuration management, and validation and verification methods.</p></li><li dir="ltr"><p dir="ltr"><strong>Evangelize MBSE Benefits</strong>: Clearly communicate the advantages of MBSE to all stakeholders, emphasizing improved efficiency, traceability, and reduced risk. Projects using an MBSE approach cost 55% less than projects using a traditional SE approach. In addition, projects using an MBSE approach delivered on time 62% of the time, compared to 59% of the time with a traditional SE approach, and up to 70% of defects have been identified during the modeling and simulation stage.</p></li><li dir="ltr"><p dir="ltr"><strong>Provide Comprehensive Training:</strong> Invest in training programs to help employees understand and adopt MBSE practices.</p></li><li dir="ltr"><p dir="ltr"><strong>Invest in the Right Tools:</strong> Carefully select and invest in MBSE tools and infrastructure, ensuring compatibility and scalability for future projects.</p></li><li dir="ltr"><p dir="ltr"><strong>Build a Culture of Continuous Improvement:&nbsp;</strong>Encourage a culture that values continuous improvement and adaptation to new methodologies. This includes fostering collaboration and open communication among all team members.</p></li></ul><h2 dir="ltr" data-element-id="headingsMap-13-0">Facilitating MBSE Adoption In Aerospace and Defense</h2><p dir="ltr">The future of MBSE in the A&amp;D sector looks promising, with increasing mandates for its adoption to avoid past pitfalls and improve project outcomes. Quest Global expertise in implementing systems engineering processes extends beyond just technical implementation. They work closely with clients to address organizational and cultural challenges, providing comprehensive training and support to ensure seamless integration of Model-Based Systems Engineering (MBSE) and digital threads. As organizations continue to recognize the benefits of MBSE, its implementation will become more widespread, leading to more efficient and effective systems engineering processes.</p><h3 dir="ltr" id="isPasted" data-element-id="headingsMap-14-0">References</h3><p dir="ltr">1. Systematic Literature Review: How is Model Based Systems Engineering Justified? Edward R. Carroll and Robert J. Malins, SANDIA REPORT SAND2016- 2607 Unlimited Release March 2016.</p>

Explore how MBSE can be used to optimize system architecture, streamline design validation, and facilitate collaboration in aerospace projects.

From Documents to Models: Improving System Architecture and  Design Validation in Aerospace With Model-Based Systems Engineering (MBSE)

<p dir="ltr" id="isPasted">The rapid technological advancements present huge challenges to the Defense &amp; Aerospace industry. As the demand for innovations rises, companies are under considerable strain to deliver advanced technologies while navigating strict timelines. Moreover, the increasing complexity of aerospace systems has made managing design, production, and operational challenges more critical than ever.</p><p dir="ltr">Companies adjust their procedures to ensure efficient and effective project execution for rising complexities and smooth system integration. Simultaneously, the industry is grappling with growing regulatory and cost pressures, as there is a heightened emphasis on reducing development times, to meet the rapidly evolving customer needs, while meeting defense and safety requirements. This balance between innovation and financial restrictions has become the industry's hallmark.</p><h2 id="isPasted">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h2><p dir="ltr">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr">Challenges Faced by the Defense &amp; Aerospace Industry</h2><p dir="ltr">Defense &amp; Aerospace programs often face the daunting task of delivering every more sophisticated systems at reduced cost and time. This demand to reduce costs and accelerate development cycles while maintaining the highest standards of quality and performance is a significant hurdle for companies operating in this sector.</p><p dir="ltr">In addition to these challenges, integrating new technologies into existing systems adds still another degree of difficulty. Companies have to incorporate these innovations while guaranteeing compatibility and best performance across all components.<sup>[1]</sup> This is further compounded by the need to manage and coordinate large, multi-functional teams, often spread across different locations and disciplines.</p><p dir="ltr">Moreover, legacy systems and outdated processes often hinder many organizations. These limitations can impede the adoption of modern digital engineering practices, which are crucial for staying competitive in today's fast-paced environment. Also, there is a growing need for real-time, accurate data throughout the product lifecycle, from design to operation, to enable data-driven decision-making and optimize performance.</p><h2 dir="ltr">Digital Solutions in Aerospace Engineering</h2><p dir="ltr">To counter the challenges discussed above, Defense &amp; Aerospace companies are increasingly turning to more integrated and digitalized product design and development solutions to. One such approach is implementing an integrated digital thread, which enable uninterrupted information flow throughout the concept, design, production, and operational stages. By creating a cohesive digital ecosystem, Defense &amp; Aerospace companies can improve collaboration, optimize processes, reduce rework and maintain data consistency across the entire product lifecycle.</p><h3 dir="ltr">Model-Based Systems Engineering (MBSE)</h3><p>Model-Based Systems Engineering (MBSE) is a powerful tool for managing the complexity of modern aerospace systems. By leveraging MBSE, engineers can create extended digital models that integrate various subsystems and components, allowing for efficient system design, simulation, and validation. This approach emphasizes using models as a central means of communication, analysis, and decision-making throughout the product lifecycle to detect potential issues early, reduce the need for physical prototypes, and facilitate better decision-making throughout development processes.<sup>[2]</sup> Additionally, MBSE facilitates collaboration among various stakeholders, assuring everyone works towards a shared understanding of the system's requirements and design.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5NTk4NDg3NDU1LWZvdXIgcXVhZHJhbnRzIG9mIHRoZSBNQlNFIG1vZGVsLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The four quadrants of the MBSE model process of system development from conceptualization to realization. Image credit:&nbsp;<a href="https://protect.checkpoint.com/v2/___https://insights.sei.cmu.edu/blog/introduction-model-based-systems-engineering-mbse/___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzoxNjJiNGNiOTM2NDJlYjYzZDA2YWFmMjBjZDYyMDdiNzo2OmVlMjk6YmY1MjllYjdmOWI5NWNjYjU0YzQwZjhjODMwYTJkMzEyMzVhZjBhN2MyZDU2OTQ3NWM4YTE5MjRjMGM3YzZkMDpwOlQ6Tg" target="_blank" rel="noopener noreferrer">Carnegie Mellon University.</a></span></span></span></p><h3 dir="ltr" id="isPasted">Digital Twins</h3><p dir="ltr">Digital twins—virtual replicas of physical systems are modifying how aerospace companies approach predictive analytics, optimization, and lifecycle management. By continuously collecting and analyzing data from sensors embedded in aircraft and other aerospace systems, digital twins provide real-time insights into system performance, facilitating proactive maintenance, improved efficiency, and heightened safety.<sup>[3]</sup> Digital twins also provide virtual testing and simulation, reducing the need for costly physical tests, hence accelerating the development approach.</p><h3 dir="ltr">Automation and Parametric Modelling</h3><p dir="ltr">Using automation tools is also a crucial digital solution, such as parametric modeling, which is essential in speeding up the design processes and optimizing performance in the aerospace industry. By altering parameters, designers can quickly explore various design options without having to start from scratch each time. It enables rapid prototyping and iteration, leading to the identification of optimal solutions and reduced time to market.</p><h3 dir="ltr">Advanced Manufacturing and Supply Chain</h3><p dir="ltr">The manufacturing sector is seeing a substantial transition with the use of Industry 4.0 technologies, including the Internet of Things (IIoT), big data analytics, and automation. These technologies facilitate the establishment of intelligent factories, wherein machines are outfitted with sensors that gather real-time data, thereby enabling communication between machines and between machines and humans. This data can be analyzed to predict and prevent equipment failures, optimize processes, and improve overall efficiency.</p><p dir="ltr">Augmented Reality (AR) is another key technology in Industry 4.0, bridging the gap between the physical and digital experiencs. AR enables technicians and engineers to access real-time information about complex machinery and equipment through wearable devices or mobile apps, thereby reducing the dependence on cumbersome manuals. The implementation of AR can significantly reduce installation and maintenance time, minimize errors and rework, and improve safety of the factory floor.</p><p dir="ltr">Quest Global is driving digital transformation in the manufacturing industry, providing solutions like <a href="https://www.quest-global.com/solutions/ar360/">Quest Global AR360</a>. This platform helps companies develop, deploy, and manage AR applications for various industries, enabling them to reinvent training content, improve classroom experiences, and reduce dependency on field machines. By leveraging AR and other Industry 4.0 technologies, manufacturers can increase production, reduce costs, and improve overall efficiency, positioning for success in the era of smart manufacturing.</p><h3 dir="ltr">Cross-Industry Best Practices</h3><p dir="ltr">Aerospace companies are also increasingly looking to adjacent industries, such as automotive and defense, to learn from their digital transformation experiences and adopt best practices to facilitate their digital journey.<sup>[4]</sup></p><h2 dir="ltr">Case Study: Digital Engineering for UK Defense (Project Agnostics)</h2><p dir="ltr">Quest Global is a leading global engineering services provider at the forefront of driving digital transformation in the Defense &amp; Aerospace industry. One such example is Quest Global's collaboration with a leading aerospace and defense company to support the Future Combat Air System (FCAS) development for the UK Ministry of Defense (MoD). The FCAS program aimed to deliver a next-generation air defense system that would ensure the UK's air superiority for decades to come.</p><p dir="ltr">The FCAS project also faced several other key challenges, including tight timeframes, budget restrictions, and the inherent complexity of developing a state-of-the-art defense system at "half time and half cost." Additionally, integrating advanced digital engineering tools was important to ensure collaboration and efficient project execution.</p><p dir="ltr">Quest Global and its partner therefore created a digital engineering solution designed to address these challenges. It advanced the project by contributing as a thought leader and implementation catalyst. The team is collaborating with the customer to discover how digital technologies may improve procedures, lower costs, and speed up development.</p><p dir="ltr">To ensure the successful implementation of this digital engineering approach, Quest Global deployed a cross-functional team of 25 highly skilled engineers. This team combined expertise from across industries, including aerospace and defense, to create a robust and innovative digital engineering environment. The team significantly reduced project timelines and improved efficiency across the board by using advanced digital tools and best practices.</p><p dir="ltr">Quest Global's approach to digital engineering, which combines deep domain expertise with cross-industry best practices, is expected to be a key differentiator in the success of the FCAS project. The company's thought leadership and innovative solutions, tailored to the specific needs of the client, aim to deliver tangible results in terms of cost reduction and timeline acceleration.</p><p dir="ltr">By working towards the goal of reducing costs without compromising quality, Quest Global is demonstrating the potential of digital technologies to transform the aerospace industry. If successful, the substantial reduction in project development times could set a new standard for efficiency in the sector, paving the way for faster, more agile development processes in the future.</p><h2 dir="ltr">Conclusion: Future Directions for Aerospace Engineering</h2><p dir="ltr">As the aerospace industry evolves, it is expected to increasingly adopt digital thread technologies, which enable easy integration and flow of data across the entire product lifecycle. The digital threads will be necessary for simplifying real-time monitoring, predictive maintenance, and enhanced lifecycle management of aerospace products. By using the digital threads, organizations can achieve improved efficiency, safety, and performance.</p><p dir="ltr">Looking ahead, the emphasis on cost and time reduction will remain a top priority for the aerospace industry, particularly in the defense sector.<sup>[5]</sup> Future projects will focus on delivering highly sophisticated systems within ever-tightening timeframes, driving the need for even more advanced digital engineering solutions and agile development methodologies.</p><p dir="ltr">The success of aerospace companies will be increasingly dependent on their capacity to acquire collaborative digital ecosystems. Organizations can accelerate decision-making, enhance innovation, and dismantle silos by establishing environments in which data circulates effectively across functions and teams. This shift towards increased collaboration and data-driven insights will be essential in addressing the numerous challenges faced by the aerospace industry.</p><h2 dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></h2><h2 dir="ltr" id="isPasted">References</h2><p dir="ltr">1. Terrile RJ. Pathways and challenges to innovation in aerospace. In2010 IEEE Aerospace Conference 2010 Mar 6 (pp. 1-7). IEEE. (Accessed on September 20, 2024)</p><p dir="ltr">2. Uckun S, Kurtoglu T, Bunus P, Tumer I, Hoyle C, Musliner D. Model-based systems engineering for the design and development of complex aerospace systems. SAE Technical Paper; 2011 Oct 18. (Accessed on September 20, 2024)</p><p dir="ltr">3. Xiong M, Wang H. Digital twin applications in aviation industry: A review. The International Journal of Advanced Manufacturing Technology. 2022 Aug;121(9):5677-92. (Accessed on September 21, 2024)</p><p dir="ltr">4. Thompson R, Patel S. Cross-industry learning: Best practices from automotive to aerospace. J Eng Manag. 2022;35(3):245-60. (Accessed on September 23, 2024)</p><p dir="ltr">5. Patel, Jay. Future of Aerospace Industry with Opportunities and Challenges. 10.13140/RG.2.2.16721.51049. (Accessed on September 23, 2024)</p>

Defense & Aerospace companies are turning to digital engineering solutions to deliver advanced technologies while meeting strict timelines and budgets.

Addressing Challenges in the Defense & Aerospace Industry with Digital Engineering Solutions

<p dir="ltr" id="isPasted">3D printing has been on the defense sector’s radar for over a decade.<sup>[1]&nbsp;</sup>However, it is only in recent years that additive technologies have matured to the point of enabling truly viable production applications for military adopters, and the potential is only just starting to be tapped.</p><p dir="ltr">Additive manufacturing technologies are well-positioned to improve several aspects of defense production processes. According to the U.S. Department of Defense’s Additive Manufacturing Strategy published in 2021, 3D printing has a number of benefits for the defense sector, including “modernizing national defense systems” through optimized AM design, producing innovative solutions and devices on the front lines and “increasing material readiness” through accelerated development and on-demand production of spare parts.<sup>[2]</sup></p><p dir="ltr">In this article, we will be exploring how these benefits are being realized by militaries and defense groups around the globe, as well as how UltiMaker’s 3D printing solutions are ideally suited to meet the stringent standards and agility required in military applications.</p><h2 dir="ltr">3D Printing Applications in Defense</h2><p dir="ltr">Applications in the defense and military sectors have been evolving steadily over the years, from rapid prototyping to various production applications that provide value in terms of efficiency, logistics, and safety. Below are the leading application areas for additive manufacturing in defense sectors around the world.&nbsp;</p><h3 dir="ltr">Spare Parts</h3><p dir="ltr">One of the most game-changing applications for 3D printing in the defense sector is the on-site production of spare parts. Since 3D printing technologies can be deployed in remote locations or even on the front lines, the technology facilitates the production of replacement parts on demand. This has huge benefits when it comes to logistics and military supply chains. For one, troops deployed in remote locations are more self-sufficient when they can print parts they need on the go. This capability also eliminates the need to transport extensive inventories of spare parts; instead, troops must simply bring a 3D printer and materials to print the parts that they need when they need them.</p><p dir="ltr">At military bases, 3D printing technologies are also valuable for spare part production. For example, if a legacy vehicle or aircraft returns with a broken or defective component, engineers can reverse engineer the part and print it on site as a stop-gap solution while the actual part is sourced through a complex supply chain. In some cases, 3D printed parts are also viable to use as permanent replacements, which simplifies supply chains even more. This is thanks to advances in production-grade 3D printing materials, such as glass and carbon fiber reinforced polymers and metal filaments.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMzI5MzA5Mjk2LXVsdGkgZGVmZW5jZSA0LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The French Army deployed 50 UltiMaker 3D printers in 2020 to overcome supply chain challenges posed by the COVID-19 pandemic. (Photo Source: 3DPrint.com)</span></span></span></p><p dir="ltr" id="isPasted">One example of leveraging 3D printing for spare parts production comes from France, where the French Army launched one of the largest military 3D printing farms in Europe in order to ease supply chain challenges caused by COVID-19. In total, 50 UltiMaker 3D printers were installed at the Ecoles Militaires de Bourges in April 2020 to produce spare parts for repairing systems and vehicles for external operations.<sup>[3]</sup> Today, the French military operates a fleet of about 200 UltiMaker 3D printers.</p><p dir="ltr">Naval units can also benefit from the ability to print replacement parts onboard ships. For example, one UltiMaker customer 3D printed a replacement cold water filter used on ships to filter sea water. Since the original filter broke down while the ship was on a mission, it was not possible to easily source a replacement using conventional methods. Using 3D printing, however, the crew was able to produce a functional replacement in a single day for only €30 (98% less than the original part) using UltiMaker PLA and TPU. The replacement part also ended up lasting longer than the original component.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMzI5MzQxMDQwLXVsdGkgZGVmZW5jZSA1LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3D printed cold water filter replacement, which only cost €30 to produce onboard a ship. (UltiMaker)</span></span></span></p><h3 dir="ltr" id="isPasted">Tools &amp; Equipment Enhancements</h3><p dir="ltr">3D printing has also proven to be a valuable manufacturing technology to military users when it comes to maintenance operations. As we saw above, spare parts play a big role in keeping maintenance and repair operations efficient, but 3D printing can also be used in other ways to streamline workflows and facilitate equipment maintenance, such as in the rapid production of custom tools and assembly aids.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMzI5MzYzNzUxLXVsdGkgZGVmZW5jZSA2LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">3D printed cold water filter replacement, which only cost €30 to produce onboard a ship. (UltiMaker)</span></span></span></p><p dir="ltr" id="isPasted">The Royal Netherlands Air Force has turned to UltiMaker 3D printing to produce a series of custom tools for the maintenance of fighter jets, helicopters, and cargo planes. Maintenance operations to keep military aircraft in top condition can be complex, as aircraft tend to have unique or rare parts. With 3D printing on site, Dutch military maintenance crews have the ability to design and iterate custom tools, such as special caps to cover jet engine openings in transport, or adjustment tools for helicopter parts that dramatically simplify configuration. In many cases, custom tools can be 3D printed in a matter of hours, which accelerates maintenance times and saves costs associated with tool outsourcing.<sup>[4]</sup></p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMzI5Mzk3Njc3LXVsdGkgZGVmZWluY2UgMy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Dual-material rotinor turbine wrench used in the maintenance of underwater transport systems. (UltiMaker)</span></span></span></p><p dir="ltr" id="isPasted">In another maintenance use case, a custom rotinor turbine wrench used to maintain an underwater transport system was 3D printed using a combination of PA CF10 and Igus’ iglidur I150-PF filament. While the original tool, made from steel, cost €1100 to manufacture and took 12 weeks of lead time, 3D printing brought the cost and lead time down to just €24 and 13 hours, respectively. Besides the time and cost benefits, 3D printing also made it possible to easily customize the tool, manufacture it on-site, and minimize the risks of system damage through the integration of the tribo filament iglidur I150-PF. &nbsp;</p><p dir="ltr">In addition to maintenance tools, 3D printing can be used on the front lines to rapidly produce components that enhance equipment capabilities. For example, troops can take the initiative to 3D print custom brackets for mounting GPS or radio communication systems in vehicles like motorcycles or quads. 3D printing makes it possible to adapt the brackets for different types of communication equipment and integrate features like microphone slots (as was the case with the 3D printed bracket pictured below). This capability not only helps reduce cost and lead times (in this case the 3D printed part was 80% cheaper than the conventional steel component and took only one day to make), it also empowers defense teams, as they iterate helpful products on an as-needed basis using materials fit for the<a href="https://ultimaker.com/learn/lifting-a-12-tonne-tank-with-a-plastic-3d-print/" target="_blank">&nbsp;toughest applications</a>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMzI5NDQ2NTgyLXVsdGkgZGVmZW5zZSAyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">GPS / Radio bracket fixes a radio communication to vehicles like motorcycles and quads during missions. (UltiMaker)</span></span></span></p><h3 dir="ltr" id="isPasted">Medical Devices</h3><p dir="ltr">The medical sector has been a key adopter of 3D printing and has benefited particularly from the technology’s ability to create patient-specific models and devices on demand. These same benefits also translate to the defense sector, where efficient medical treatment is imperative. Having a 3D printer on a base or in the field enables medical teams to rapidly design and iterate potentially life-saving devices, such as patient-specific surgical planning tools or customized prosthetics, even in remote regions.</p><p dir="ltr">Leveraging 3D printing in the production of medical models and devices is not only important to treat military personnel, it can also be deployed in disaster zones to ensure patients receive the care they need and are fitted with custom prosthetic or orthotic devices even when infrastructure and traditional supply chains have failed.</p><h2 dir="ltr">Technological Advancements and Innovations</h2><p dir="ltr">In addition to the aforementioned applications, there are many cutting-edge research and development initiatives to advance additive manufacturing in the defense sector. Below are just a few examples of avenues that militaries and defense researchers are exploring for the use and optimization of additive technologies:</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;High-performance protective gear and armor that leverages advanced 3D printed materials, metamaterials, and bio-inspired design.</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;3D printed shelters, barracks, and bunkers made using large-format construction 3D printing systems capable of building in-situ using locally sourced materials.<sup>[5]</sup></p><p dir="ltr">● &nbsp; &nbsp; &nbsp;AI-driven software to enhance and further automate part design as well as increase the efficiency and consistency of production processes.<sup>[6]</sup></p><h2 dir="ltr">UltiMaker Solutions for Defense&nbsp;</h2><p>Finding the right 3D printing solution for defense applications can be a challenge, as military organizations have many considerations and requirements related to deployability, security, and quality. UltiMaker’s industrial desktop systems, which are now in use for several <a href="https://ultimaker.com/applications/defense/" target="_blank">defense applications</a> around the globe, are a viable solution for defense users seeking to exploit the benefits of 3D printing. For example, UltiMaker’s 3D printing systems—including the <a href="https://ultimaker.com/3d-printers/s-series/" target="_blank">S series</a>, <a href="https://ultimaker.com/3d-printers/method-series/" target="_blank">Method series</a>, and Factor series—offer:</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;An enclosed and fully protected print chamber, which enables them to be used in challenging environments. (The<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank">&nbsp;Factor 4</a> features a triple-insulated build chamber.)</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;Dual-extrusion capabilities for multi-material builds, easy-to-remove supports, or faster printing rates.</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;A compact footprint, which facilitates the deployment of 3D printers to remote locations in the field or onboard ships.</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;The option of a materials case that protects filaments and ensures materials are stored at the right temperature and humidity levels. (In the case of the Factor 4, the system has a built-in automated material handling system.)</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;A high-level of security and IP protection, since UltiMaker machines and Cura software can be used without cloud connection; all designs and 3D prints can be saved within an organization’s own secure data bubble.</p><p dir="ltr">● &nbsp; &nbsp; &nbsp;Broad material options, including high-strength and high-performance filaments, such as<a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">&nbsp;carbon fiber reinforced polyphenylene sulfide (PPS CF)</a>,<a href="https://ultimaker.com/materials/s-series-pet-carbon-fiber/" target="_blank">&nbsp;PET CF</a>,<a href="https://ultimaker.com/materials/s-series-pc/" target="_blank">&nbsp;Polycarbonate (PC)</a>,<a href="https://ultimaker.com/materials/s-series-tpu-95a/" target="_blank">&nbsp;flexible TPU</a>, and even metal filaments like<a href="https://ultimaker.com/materials/ultimaker-metal-expansion-kit/" target="_blank">&nbsp;Ultrafuse 17-4 PH</a>. The UltiMaker Factor 4 is also compatible with over <a href="https://marketplace.ultimaker.com/app/cura/materials" target="_blank">200 third-party materials</a>.</p><p dir="ltr">In addition to these technical advantages, UltiMaker is also a reliable partner for defense companies and organizations, and is committed to building long-lasting relationships with its clients and ensuring that all needs are met. The company even offers consultancy services that can help end users in the defense sector make the most out of 3D printing and discover innovative new ways of leveraging the technology. &nbsp;&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 790px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyMzI5NTU1ODMyLXVsdGkgZGVmZW5zZSAxLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">UltiMaker Factor 4 was presented at AM Village, Tournai/Belgium (UltiMaker)</span></span></span></p><h2 dir="ltr">Advancing Defense Goals</h2><p dir="ltr">Ultimately, 3D printing technologies are empowering military organizations to achieve greater efficiency and accelerate innovation, both on bases and in the field. As in other industries like aerospace and automotive, the technology has proven to be uniquely capable of manufacturing critical replacement parts and equipment enhancements on location. In a military context, this is especially valuable as being able to produce components on the go improves operational readiness and ensures critical equipment is kept up and running.</p><p dir="ltr">As we’ve seen, this capability is also game-changing for military logistics and supply chains. Troops deployed in the field or Navy crews can benefit significantly from the ability to manufacture parts when they are needed rather than transporting a large inventory of spare parts or waste significant time sourcing parts through complex supply chains. This versatility means that defense teams simply have to transport a 3D printer and raw materials and can create a wide variety of parts on demand. All in all, additive manufacturing’s capabilities align almost seamlessly with the goals of military applications, with a notable emphasis on customization, adaptability, and innovation.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Cheney-Peters, Scott; Hipple, Matthew. Print Me a Cruiser! [Internet]. U.S. Naval Institute, April 2013.<a href="https://www.usni.org/magazines/proceedings/2013/april/print-me-cruiser" target="_blank">&nbsp;https://www.usni.org/magazines/proceedings/2013/april/print-me-cruiser</a></p><p dir="ltr">&nbsp;</p><p dir="ltr">[2] DoD Additive Manufacturing Strategy [Internet]. Department of Defense, January 2021.<a href="https://www.cto.mil/dod-additive-manufacturing-strategy/" target="_blank">&nbsp;https://www.cto.mil/dod-additive-manufacturing-strategy/</a></p><p dir="ltr">&nbsp;</p><p dir="ltr">[3] Tampi, Tarun. French Army Deploys Massive Military Print Farm for Spare Parts [Internet]. 3DPrint.Com, July 7, 2020.<a href="https://3dprint.com/269936/french-army-deploys-massive-military-print-farm-for-spare-parts/" target="_blank">&nbsp;https://3dprint.com/269936/french-army-deploys-massive-military-print-farm-for-spare-parts/</a></p><p dir="ltr">&nbsp;</p><p dir="ltr">[4] Royal Netherlands Air Force: Speeding up maintenance with 3D printed tools [Internet]. UltiMaker, 2024.<a href="https://ultimaker.com/learn/royal-netherlands-air-force-speeding-up-maintenance-with-3d-printed-tools/" target="_blank">&nbsp;https://ultimaker.com/learn/royal-netherlands-air-force-speeding-up-maintenance-with-3d-printed-tools/</a></p><p dir="ltr">&nbsp;</p><p dir="ltr">[5] Riebeling, Alyx. New innovative Army effort builds 3D printed barracks [Internet]. U.S. Army, February, 2024.<a href="https://www.army.mil/article/274036/new_innovative_army_effort_builds_3d_printed_barracks" target="_blank">&nbsp;https://www.army.mil/article/274036/new_innovative_army_effort_builds_3d_printed_barracks</a></p><p dir="ltr">&nbsp;</p><p dir="ltr">[6] Decker, Audrey. Air Force tests AI-designed, 3D-printed drones [Internet]. Defense One, June, 2024.<a href="https://www.defenseone.com/technology/2024/06/air-forces-mideast-drone-unit-eyes-stateside-element/397257/" target="_blank">&nbsp;https://www.defenseone.com/technology/2024/06/air-forces-mideast-drone-unit-eyes-stateside-element/397257/</a></p>

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