The aerospace sector has been hit by COVID like no other. For aircraft manufacturers, production ramp-up issues have suddenly become a thing of the past, as orders are being delayed or worse, cancelled. So, what to do in a world where demand has plunged? Preparing for a better future seems to be the only answer.

Now is the time to assess how the landscape of the industry has shifted to designing the aerospace of the future.” Amid the pandemic, Airbus is unveiling plans for its first hydrogen fueled “zero emission planes” and governments across the world are finally offering funding to ramp up the digital transformation. Now is the time for OEMs to deploy digital capabilities to prepare manufacturing operations for business recovery: gain agility to launch new programs faster than ever before, to reach greater levels of industrial efficiency, and to emerge from the crisis with greener and leaner processes – less scrap, more throughput, more profitability.

Digitalization also supports engineering teams reach their quality, performance, safety, and sustainability targets, while meeting strict regulations, production agility, and program costs. In this new world we find ourselves in, stand-alone CAD design using empirical and historical safety margins and traditional test-and-learn protocols relying on physical testing will be abandoned for digital solutions allowing teams to validate a design’s performance, assess its manufacturability, and define the most efficient manufacturing process.

This is what we, at ESI, call Virtual Prototyping.

Cabin and Cockpit of the Future: Make the Right Decisions Early

Enhancing the overall passenger experience is critical to ensure that your aircraft interior and seat design meet the proper quality, comfort, and acoustic requirement without hindering on-time certification, safety, and production targets. The challenge is difficult for engineers, as seat and cabin components are prone to regular innovation. Driven by a necessity to ensure precertification, both OEMs and seat manufacturers must deliver innovative designs within a specific budget and without hindering comfort, safety, and production. Virtual Prototyping empowers seat engineers to evaluate the performance and comfort in the early design phases by fully exploring, testing, improving, and pre-certifying the seats & cabin virtually, therefore, removing the need for physical prototypes before production.

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Experience Your Products & Processes Like You Would the Real Thing

As design sets the stage for manufacturing and service, engineering teams must recognize people's interactions with their intended products and processes to ensure ease of production and maintenance. Using Virtual Reality during the design and industrialization review process to conduct humancentric assembly and maintenance validations significantly reduce risks to operator safety, improves on-time delivery, delivers repeatable quality, and ultimately improves product profitability.

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Ensure High Precision, High Quality Parts at the Lowest Cost

Virtual Prototyping is one of the most innovative ways to minimize cost overruns, prove manufacturability, and process consistency. For airframes and aero-engine components, Virtual Manufacturing accelerates the development and validation of key manufacturing processes to fabricate complex and lightweight quality components. By applying standard development and production processes, smart manufacturers virtually streamline manufacturing capabilities, secure novel production techniques such as additive manufacturing, and develop & validate composite designs. With casting simulation, foundry professionals understand each process parameter's impact on the final part quality and fine-tune the entire casting manufacturing process.

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