The traditional engineering processes ensure that safe and robust products are being developed. However, the growing demand for innovative solutions in short time scales drives the need for a cultural change in the way we work in engineering. Looking at the traditional product life cycle we see that important design decisions tend to be made early during the concept design phase before detailed analysis or test data are available. Data analysis techniques in combination with classical engineering tools can practically help to resolve that conflict by making more useful information available earlier in the process. Consequently the entire process can become more effective.

In this eGuide, we’ll address key aspects of digital twin technology and highlight case studies of an aerospace company successfully using digital twin technology to streamline development and save money.

When it comes to manufacturing innovative aerospace technologies, the product development and analysis process can be long and tedious. As part of their new generation launch vehicle and spacecraft engine product offerings, Astra was looking for a way to streamline their product development life cycle. While they intended to improve speed and efficiency, it was important that Astra’s team not lose accuracy within their data and remain consistent with their pre-existing test results. With Altair SimSolid, Astra was able to build and analyze better, more reliable products faster. It allowed Astra to perform the expected workload they needed, producing robust results and accurate reporting in a tenth of the time it took other in-house tools currently in use.

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Unmanned aerial systems (UAS) are a rapidly evolving technology and used for a variety of civil and military purposes. To ensure airworthiness, UAS manufacturers rely on advanced simulation and manufacturing techniques to create efficient designs. Aerial systems active throughout Europe and operating with diverse payloads for different missions require a reliable vehicle architecture and fuel supply. To ensure perfectly tuned architecture and a lightweight design while increasing stiffness and strength, Schiebel used Altair solutions in combination with 3D printing. The engineers performed various simulations to optimize the design of AM engine parts. Using Altair’s topology optimization structural design tool, Schiebel reduced the weight significantly while maintaining high stiffness. Subsequently, the system was evaluated by laminar and turbulent flow simulation as well as conjugate heat transfer simulation using Altair CFD™. Contacts, NLFE and complex dynamic systems were modeled with Altair® MotionView® and Altair® MotionSolve®. Schiebel also took advantage of APA solutions.