<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><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>

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 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">Manufacturers operate in a rapidly evolving environment with a unique set of challenges. Global competition drives them to reduce costs while meeting rising quality expectations. There's also a race to achieve faster time-to-market to attract and retain clients. Meanwhile, government and industry bodies around the globe have been enforcing stringent sustainability mandates. To meet these targets, manufacturers work towards reducing greenhouse emissions and adopt circular economy practices.</p><p dir="ltr">On top of this, the pace of technological advancement presents another challenge. Staying competitive requires manufacturers to adopt new technologies, which often comes with high upfront costs and can disrupt established workflows. As teams adjust to new workflow, productivity can temporarily dip, which creates strain.</p><p dir="ltr">To overcome these challenges, manufacturers need data-driven strategies to boost accuracy, productivity, and adaptability. Intergrating digital solutions is the way forward as it helps make informed decisions to streamline processes and stay competitive in an every-changing industry.</p><h3 dir="ltr">The Rise of Smart Manufacturing: A Transformation Underway</h3><p dir="ltr">The fourth industrial revolution, or Industry 4.0, is helping manufacturers integrate digital technologies such as automation, AI, cloud computing, and IoT to create smart factories where machinery, sensors, and software are connected. With real-time data collection and intelligent analytics, companies can detect inefficiencies and make informed decisions to optimize processes.</p><p dir="ltr">As a leader in this space, Hexagon offers integrated manufacturing intelligence that spans from design to the final product. By providing tools for design, simulation, and quality management, Hexagon enables manufacturers to adopt processes that drive precision, sustainability, and adaptability.</p><table style="width: 100%;"><tbody><tr><td style="width: 100%; vertical-align: top;"><h2 dir="ltr" id="isPasted">Hexagon Live in Eindhoven: Insights, Innovation, and Networking</h2><p dir="ltr" id="isPasted">On November 27th and 28th Hexagon presents participants the chance to engage first-hand with their manufacturing solutions at Hexagon Live. The event also provides an opportunity to build connections with like-minded professionals, opening doors for future collaborations and growth opportunities.By interacting with thought leaders, visitors can gain valuable knowledge that can help them tackle challenges in their businesses.</p><ul id="isPasted"><li dir="ltr" style="font-weight: bold;"><p dir="ltr"><strong>27 November – Strategic Insights – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></strong></p></li><li dir="ltr" style="font-weight: bold;"><p dir="ltr"><strong>28 November – Technology Deep-Dive – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></strong></p></li></ul></td></tr></tbody></table><h2 dir="ltr">The Need for Advanced Digital Manufacturing Technologies</h2><h3 dir="ltr">Addressing Industry Challenges</h3><p dir="ltr">Manufacturers face a range of challenges that impact every stage of the production cycle. One of the most pressing is supply chain instability, caused by factors such as natural disasters, trade restrictions, and pandemics. These disruptions can delay production in today's globally distributed supply chains.</p><p dir="ltr">Energy and resource efficiency have become critical priorities due to fluctuating energy prices fueled by current geopolitical tensions. High energy costs increase production expenses, trimming already slim margins.</p><p dir="ltr">Equipment downtime poses another key efficiency roadblock. Not only does it require costly repairs but also ends up wasting valuable man-hours. The rising demand for customized products adds to these challenges. Manufacturers are now required to frequently perform time-consuming reconfiguration tasks to accommodate a wider variety of designs.</p><h3 dir="ltr">Solving Challenges with Digital Innovation</h3><p dir="ltr">Digital solutions are addressing core challenges in energy efficiency, downtime reduction, and product customization. While implementing these technologies requires an initial investment, they provide long-term benefits.</p><p dir="ltr">To manage high energy costs, manufacturers are adopting IoT-based energy monitoring and automation systems. These systems utilize sensors and smart controls to optimize energy consumption in real time. For instance, occupancy sensors can detect activity in different areas, adjusting lighting and HVAC systems to minimize energy waste.</p><p dir="ltr">Predictive maintenance has proven effective in minimizing unplanned equipment downtime. The system leverages historical data analysis, real-time machine health monitoring, and machine learning. When an anomaly or potential failure pattern is identified, the system alerts engineers to perform maintenance before a breakdown occurs.</p><p dir="ltr">In response to increasing demand for customized products, manufacturers are turning to digital twins. By creating virtual replicas of production systems, engineers can simulate and test custom designs before production begins, accelerating the design-to-manufacturing cycle. Additionally, companies are deploying flexible manufacturing systems (FMS), which feature modular workstations that can be retooled quickly. This flexibility allows manufacturers to easily switch between different product designs without requiring extensive modifications to the factory setup.</p><h2 dir="ltr">Driving the Manufacturing Intelligence Transformation</h2><p dir="ltr">Hexagon’s intelligence solutions integrate into the manufacturing ecosystem by seamlessly connecting tools, technologies, and data throughout entire production cycles. At the heart of this integration is the use of advanced tools such as digital twins, automation systems, and simulations. This integration allows data collection from each stage of the process allowing teams to monitor progress more effectively.</p><p dir="ltr">Metrology tools help companies ensure that components and products meet exact specifications, maintaining precision throughout production. This minimizes extensive rework and material waste caused by incorrect tolerances. Hexagon enhances this process by providing in-process measurement systems that monitor and measure parts directly on the production line.</p><p dir="ltr">Hexagon's innovative solutions enable real-time collaboration between design and production teams. Through digital simulation, manufacturers can optimize designs before production begins. The ability to check components digitally reduces development time, minimizes material waste, and enhances safety in industries like automotive and electronics.</p><p dir="ltr">The company combines automation technologies with its cutting-edge software to optimize manufacturing workflows. By integrating real-time data, it enhances process efficiency and improves operational outcomes.</p><p dir="ltr">Its predictive maintenance solutions identify potential issues so that engineers can address problems before they cause costly breakdowns. Such practices ensure smooth operations and extend the lifespan of equipment. Hexagon’s IoT-enabled energy monitoring tools further support sustainability efforts. These tools help companies pinpoint inefficiencies, reduce waste, and optimize resource usage.</p><h3 dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5Njg0NzkxLUhleGFnb25NSVJRMjAxOFBvZDgwMHg0MjhEZXNpZ25FbmdpbmVlcmluZ0ljb24oMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Through digital simulation, manufacturers can optimize designs before production begins. Source:&nbsp;<a href="https://hexagon.com/company/divisions/manufacturing-intelligence/what-we-do/design-engineering" target="_blank" rel="noopener noreferrer">Hexagon</a>.</span></span></span></h3><h3 dir="ltr">Support and Success</h3><p dir="ltr">Hexagon supports some of the world’s leading organizations in various industries. For example, the iconic Red Bull Racing Formula 1 team relies on Hexagon’s metrology equipment and scanners to ensure the precision needed to build their cutting-edge car.</p><p dir="ltr">Volkswagen Group’s ŠKODA AUTO also uses Hexagon’s automated measurement systems across its manufacturing facilities to enhance production accuracy and capacity.</p><p dir="ltr">Additionally, CERN, the organization dedicated to uncovering the mysteries of the universe, trusts Hexagon’s solutions to monitor its entire technical infrastructure, ensuring seamless operations for groundbreaking research.</p><p dir="ltr">For more success stories, <a href="https://hexagon.com/resources/customer-success-stories">click here</a>.</p><h2 dir="ltr">What to Expect at Hexagon Live in Eindhoven: Insights, Innovation, and Networking</h2><h3 dir="ltr">Gain Exclusive Knowledge from Manufacturing Experts &amp; Network with Industry Innovators</h3><p dir="ltr">On November 27th and 28th Hexagon presents participants the chance to engage first-hand with their manufacturing solutions at Hexagon Live. The event also provides an opportunity to build connections with like-minded professionals, opening doors for future collaborations and growth opportunities.By interacting with thought leaders, visitors can gain valuable knowledge that can help them tackle challenges in their businesses.</p><h3 dir="ltr">Content Tailored to Your Needs: Innovation and Problem-Solving</h3><p dir="ltr">The event offers a range of sessions designed to tackle real-world challenges within the manufacturing sector.</p><p dir="ltr">Hear from companies that have successfully navigated manufacturing challenges with the help of digital innovations. These case studies highlight what's possible and serve as a framework for your strategic planning.</p><h3 dir="ltr">Hands-On Exploration of Digital Reality Solutions</h3><p dir="ltr">The event offers a chance to experience how Hexagon's digital reality tools improve operational efficiency. Visitors get an understanding of how to leverage real-time data, machine learning, and automated workflows to optimize every stage of their operations, from design to delivery.</p><h2 dir="ltr">Explore the Manufacturing of Tomorrow at The Experience Center</h2><p dir="ltr">Hexagon's new Experience Centre in Eindhoven brings the future of manufacturing to life, offering visitors a chance to see how cutting-edge technologies are reshaping the industry. Being one of the first of its kind in Europe, the center promises an immersive experience where you can explore&nbsp;emerging trends, solutions, and new products first-hand.&nbsp;From reimagining production lines to real-time energy monitoring, the center showcases how facilities are evolving to meet the demands of next-generation aircraft and electric vehicles.</p><blockquote><p dir="ltr">“It’s about creating a memorable “wow” factor, leaving visitors inspired by a company offering robust solutions to today’s challenges and a visionary partnership for the future. Experience Centres have the potential to be game-changers.”</p></blockquote><p dir="ltr"><em>Marcel Brand, Senior Director Global Events &amp; Experience Centres<br>Hexagon, Manufacturing Intelligence division</em></p><p dir="ltr">In addition to theory, attendees can get hands-on with the PRESTO system and discover how automation is transforming quality control by improving precision and drastically reducing inspection times.</p><p dir="ltr">Explore the HxGN Machine Trainer, a digital twin simulator used by industry leaders like Safran to train CAM programmers and machine tool operators quickly and safely. Visitors can also experience CMM machines and 3D scanners up close, gaining insights into the latest technologies driving innovation in aerospace, automotive, and electronics manufacturing.</p><h2 dir="ltr">Hexagon Live Day 1: 27 November – Strategic Insights</h2><h2 dir="ltr"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" class="link"></a></h2><h3 dir="ltr" id="isPasted">Practical Innovation Workshops</h3><p dir="ltr">The workshops at the event are designed to address challenges in managing complex semiconductor supply chains. Experts will help attendees understand how to streamline operations to manage global disruptions and enhance supply chain resilience to ensure material availability.</p><p dir="ltr">Visitors can discover how to utilize data and automation to optimize processes in the energy industry. From increasing efficiency to reducing waste, these strategies can improve operations at every level.</p><p dir="ltr">The event touches also upon the latest technologies in energy production and distribution, with a focus on how AI and machine learning are helping in energy forecasting and demand management. You'll learn practical approaches for integrating renewable energy sources into existing infrastructure.</p><p dir="ltr" id="isPasted"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" class="button-main-action">Register Now</a></p><h3 dir="ltr">Insightful panel discussions</h3><p dir="ltr">The company will also host panel discussions featuring industry leaders and experts who will share their perspectives on industry advancements.</p><p dir="ltr">These discussions will explore how technologies digital twins and simulation are accelerating design and product development cycles in both aerospace and automotive manufacturing.</p><h3 dir="ltr">An F1 Engineering Marvel Up Close&nbsp;</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMyMjA5ODc0ODg0LU9yYWNsZS1SZWQtQnVsbC1SYWNpbmctY2FzZXN0dWR5LWJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The Hexagon Live event will also feature a keynote session from the Oracle Red Bull giving insight into how they leverage Hexagon's technology for success. Source:&nbsp;<a href="https://hexagon.com/resources/resource-library/hexagon-measurement-keeps-productivity-track" target="_blank" rel="noopener noreferrer">Hexagon</a>.</span></span></span></p><p dir="ltr">Who better to offer insights on staying ahead of the competition than Oracle Red Bull Racing? This legendary team has secured 6 Constructors' Championships and 7 Drivers' Championships.</p><p dir="ltr">Competing against the best in the world leaves Red Bull Racing with no margin for error. Don’t miss Red Bull’s keynote to learn how Hexagon helps the team achieve unparalleled accuracy, efficiency, and speed in a sport where just one-tenth of a second can make all the difference.</p><h2 dir="ltr">Hexagon Live Day 2: 28 November – Technology Deep-Dive</h2><h3 dir="ltr">In-Depth Exploration of Technical Breakthroughs</h3><p dir="ltr">On the second day of the event, attendees will get to discover the latest metrology solutions, including in-process measurement that integrates metrology directly into the production phase. The session will also cover the impact of these innovations on quality control processes.</p><p dir="ltr">Next, visitors can explore finite element analysis (FEA) simulation techniques, which utilize digital models to simulate how objects behave under forces to predict real-world results. It will be followed by a deep dive into advanced design, feasibility, and cost optimization for sheet metal components.</p><p dir="ltr"><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home" id="isPasted" class="button-main-action">Register Now</a></p><h3 dir="ltr">Gain Innovative Perspectives</h3><p dir="ltr">The event will highlight how non-contact reality capture offers real-world analysis with precise 3D representations of environments. Attendees will learn how this technology enables engineers, builders, and forensic teams to ensure no critical details are overlooked. With edge computing, they can validate data accuracy directly on-site, streamlining the process and improving outcomes.</p><h2 dir="ltr">Ready to Be a Part of the Future? Register Now for Hexagon Live!</h2><p dir="ltr">Hexagon Live offers a unique opportunity to explore the latest in manufacturing innovation and gain valuable insights to stay ahead in this ever-changing industry.</p><p dir="ltr">Discover advanced solutions like automation and digital twins, designed to boost efficiency and improve quality. Attend discussion panels and workshops to connect with leading professionals and gather expert knowledge.</p><p dir="ltr">Best of all, general admission is completely free. What are you waiting for? Use the following links to reserve your spot today!</p><ul><li dir="ltr"><p dir="ltr">27 November – Strategic Insights – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></p></li><li dir="ltr"><p dir="ltr">28 November – Technology Deep-Dive – <a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven/home">Register Now</a></p></li></ul><p dir="ltr"><strong>Unable to attend? Wevolver will be livestreaming the event on our&nbsp;</strong><a href="https://www.linkedin.com/company/wevolver/"><strong>Linkedin</strong></a><strong>&nbsp;and </strong><a href="https://x.com/WevolverApp?ref_src=twsrc%5Egoogle%7Ctwcamp%5Eserp%7Ctwgr%5Eauthor" target="_blank" rel="noopener noreferrer"><strong>Twitter</strong></a><strong> page on November 27th.&nbsp;</strong><a href="https://www.linkedin.com/company/wevolver/mycompany/#:~:text=Message-,Following,-Home" target="_blank" rel="noopener noreferrer"><strong>Follow us</strong></a><strong>&nbsp;to get a notification on the day so you don't miss a moment!</strong></p>

Learn how manufacturers are leveraging IoT, AI, and automation to tackle global competition, meet sustainability goals, and enhance customization at Hexagon Live on November 27th-28th.

Step into the Center of Future Manufacturing: Experience Intelligent Manufacturing Solutions at Hexagon Live

<p id="isPasted">Satellite sensors are used for Earth observation, navigation and positioning, telecommunications, military missions, and scientific research. Custom sensors have specialized capabilities, but commercial off-the-shelf (COTS) products that use advanced technologies can reduce development and launch costs.&nbsp;</p><p>If you’re selecting satellite sensors, consider these four factors.</p><ol start="1" type="1"><li>Sensor type</li><li>Performance specifications</li><li>Environmental considerations</li><li>Integration with satellite systems</li></ol><p>The following sections explain.</p><h2>#1 Sensor Types</h2><p>Satellites are equipped with a variety of sensors, including some that are redundant to ensure continued operations in the event of device failure. The type of sensor to select is a function of your application requirements and the device’s capabilities.</p><h3>Optical Sensors</h3><p><a href="https://www.mouser.com/c/sensors/optical-sensors/?srsltid=AfmBOopLoBeb_e87pPGBojAgJIghB1oK08NvEPMH4Vkz5TKRXeVkyrv-">Optical sensors</a> detect light within specific spectral ranges, such as visible and infrared (IR), for imaging, monitoring, and navigation. They are highly accurate, compact, lightweight, and can support high-bandwidth transmissions. For satellites with directional antennas, optical sensors are used for positioning, tracking, and alignment. For laser communications with ground stations, these satellite sensors support very fast transmissions. &nbsp;</p><h3>Radar Sensors</h3><p><a href="https://www.earthdata.nasa.gov/learn/backgrounders/what-is-sar">Synthetic aperture radar (SAR)</a> sensors combine multiple radar signals collected over time as a satellite moves in orbit. They support high-resolution imaging without the use of a large antenna. Unlike optical sensors, SAR operates in the microwave range of the electromagnetic spectrum. Among their advantages, radar sensors can capture images regardless of lighting or cloud cover.</p><h3>Gyroscopes and Accelerometers</h3><p><a href="https://escies.org/download/webDocumentFile?id=1056#:~:text=Guidance%2C%20navigation%20and%20control%20systems,and%20stabilization%20of%20its%20attitude.">Gyroscopes</a> measure angular velocity and help satellites maintain their orientation in flight.<a href="https://metromatics.com.au/applications-for-accelerometers/#:~:text=Accelerometers%20in%20Space&text=Accelerometers%20measure%20the%20vibration%20and,of%20the%20vehicles%20during%20operation.">&nbsp;</a><a href="https://metromatics.com.au/applications-for-accelerometers/#:~:text=Accelerometers%20in%20Space&text=Accelerometers%20measure%20the%20vibration%20and,of%20the%20vehicles%20during%20operation.">Accelerometers</a> measure linear acceleration and can determine shock and vibration levels during launch, flight, and landing. There are also piezoelectric accelerometers, capacitive accelerometers, mechanical gyroscopes, ring laser gyroscopes (RLGs), and fiber optic gyroscopes (FOGs), each suited to specific applications.</p><h3>Magnetometers</h3><p><a href="https://www.pnisensor.com/understanding-magnetometers-and-their-uses/">Magnetometers</a> are sensors that measure changes in magnetic fields. They are essential for navigation and are used in conjunction with gyroscopes and accelerometers for attitude determination and motion tracking. Subtypes include fluxgate, optically pumped, SQUID, hall effect, magneto-resistive (MR), and Lorentz force magnetometers.</p><h3>Thermal Infrared Sensors</h3><p><a href="https://up42.com/blog/introduction-to-thermal-infrared">Thermal infrared sensors (TIR)</a> measure land surface temperatures and detect heat signatures. Unlike near-infrared (NIR) and shortwave infrared radiation (SWIR) devices, TIR technology senses emitted energy rather than reflected energy. With their high spatial resolution, TIR sensors can attribute temperature values to specific features, such as urban heat islands.</p><h3>Radio Frequency Sensors</h3><p>Radio frequency (RF) sensors detect and measure RF signals for applications that include signals intelligence (SIGINT) and environmental monitoring. By triangulating signals from multiple orbital points,<a href="https://newspaceeconomy.ca/2023/09/05/what-are-radio-frequency-rf-monitoring-satellites/#:~:text=Advanced%20RF%20sensors%20aboard%20satellites,classification%20and%20detection%20of%20patterns.">&nbsp;</a><a href="https://newspaceeconomy.ca/2023/09/05/what-are-radio-frequency-rf-monitoring-satellites/#:~:text=Advanced%20RF%20sensors%20aboard%20satellites,classification%20and%20detection%20of%20patterns.">RF sensors</a> for SIGINT can identify distinct emitters and find their precise location. For environmental monitoring, RF sensors can track signals regardless of weather conditions.</p><h3>GNSS Sensors</h3><p>Global navigation satellite system (<a href="https://www.geo-instruments.com/technology/gnss-sensors/">GNSS</a>) sensors provide autonomous geo-spatial positioning. As satellites orbit the Earth, they transmit a unique signal along with orbital parameters. Ground-based receivers use this information to calculate a user’s exact location. GNSS encompasses a variety of satellite-based systems, including the U.S. global positioning system (GPS).</p><h2>#2 Performance Specifications</h2><p>Satellite sensors differ in terms of performance specifications. Depending on the specific application, some specs may be more important than others. For example, Earth observation requires sensors with high spatial resolution to distinguish small objects on the ground from their surroundings.</p><h3>Frequency Range</h3><p>Frequency range is the range of frequencies over which a satellite sensor is designed to operate. It determines the sensor’s ability to capture specific signals, perform remote sensing tasks, or transmit and receive data. Different sensors are designed to operate within different frequency bands, such as the ultra-high frequency (UHF) band within the RF portion of the electromagnetic spectrum.</p><h3>Resolution</h3><p>Resolution refers to a sensor’s ability to distinguish between closely spaced objects or fine details. There are different types of resolution, including spatial, spectral, temporal, radiometric, and angular resolution. Satellite sensors with higher resolution can acquire more data, but they also need more storage and processing power. In addition, higher resolution sensors are more expensive.</p><h3>Sensitivity</h3><p>Sensitivity refers to the ability of a sensor to detect small changes or weak signals in the quantity it’s designed to measure. Depending on the type of space sensor, this quantity could be IR or visible light, magnetic fields, temperatures, or RF signals. With SAR sensors, sensitivity determines how well the radar can detect small, reflected signals from objects on Earth’s surface. &nbsp; &nbsp; &nbsp;&nbsp;</p><h3>Power Consumption</h3><p>Sensor power consumption refers to the amount of electrical power that a sensor uses. It includes the power that’s consumed by the sensor itself for signal detection and the power used by supporting electronics for signal amplification, processing, or transmission. Because satellites have limited power availability, sensors with low power consumption are preferred.</p><h3>Weight and Size</h3><p>Sensor weight and size are important because satellites have strict payload limitations. These specifications can also affect larger design decisions and overall sensor performance. For example, the size of an optical sensor that’s used with a satellite’s camera determines how much light the camera has available to create an image. In turn, this affects image quality.</p><h2>#3 Environmental Considerations</h2><p>When selecting a satellite sensor, consider the environment in which it will be used. Outer space exposes sensors to extreme conditions, and repairing or replacing components can be challenging.&nbsp;</p><ul><li><strong>Radiation Tolerance</strong>: Space environments expose sensors to high levels of ionizing radiation, which can degrade performance over time. Choose sensors and other electronic components that are radiation-hardened.</li><li><strong>Temperature Variations</strong>: Satellites face extreme temperature fluctuations, and sensors need to function reliably under these changing conditions. Depending on whether a satellite is in sunlight or shadow, temperatures can range from -270°C to +200°C.</li><li><strong>Outgassing and Vacuum</strong>: Choose sensors that are built from materials that do not outgas in the vacuum of space. Outgassing, the process by which materials release trapped gasses when exposed to vacuum pressure, can cloud optical lenses and interfere with signals.</li></ul><h2>#4 Integration with Satellite Systems</h2><p>When selecting satellite sensors, consider how the device will integrate with larger systems that are essential for continuous operations. There are several systems that are especially critical.</p><h3>Data Handling and Communications</h3><p>Command and data handling (CDH) systems acquire, process, store, format and downlink data to ground-based assets. They include various subsystems, such as telemetry and telecommunications (TTC). For real-time or delayed data transmissions, choose sensors that are compatible with the satellite’s onboard data handling system.</p><h3>Pointing and Stabilization</h3><p><a href="https://www.satnow.com/search/antenna-pointing-mechanisms">Antenna-pointing mechanisms</a> direct a satellite’s antenna toward a specific communication target. A control system receives data that’s acquired from sensors, calculates the required rotation of the antenna, and stabilizes the device. Depending on the sensor type and application, pointing and stabilization may also be used with high-resolution cameras.&nbsp;</p><h3>Power Monitoring</h3><p>Satellites have multiple subsystems, each of which requires different amounts of power. Each subsystem must receive the correct voltage and current, and without power spikes or other anomalies that can jeopardize performance. Power monitoring systems for energy generation and storage must work with satellite sensors and support the use of onboard solar panels and batteries.</p><p>Are you looking for satellite sensors? <a href="https://www.mouser.com/c/sensors/?srsltid=AfmBOoroprtuwE_0UkwpJGlpiyyQxfRCl337OHfi9U8LZ_YkVUuPqpRZ">Visit Mouser Electronics.</a></p>

The Arctic Weather Satellite is collecting data in one of the regions of our planet that is most severely affected by climate change. ©OHB Sweden

Key Considerations for Selecting Satellite Sensors: Types, Performance, Environment, and Integration

How to Select Satellite Sensors: Five Key Considerations

<p dir="ltr" id="isPasted"><a href="https://protect.checkpoint.com/v2/___https://www.mdpi.com/2071-1050/15/23/16206___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OjJjZmQ6MmJmOGFlZWYwNjYyNjI0OWU4ZTc0YTg5MTJjYjQ0ZjdhN2NiYjIzYzIwMTZmNTVhNGExMGY1MzhmY2IxMDFlZTpwOlQ6Tg">The aerospace industry is a highly regulated and precision-driven industry</a>, where operational excellence is not simply a goal, but rather a top priority. Aerospace manufacturers are under constant pressure to meet the highest quality standards while at the same time optimizing production efficiency and managing complex supply chains. One of the key challenges in this sector is the management of non-conformances (NCs), which can lead to costly delays, safety risks, and decreased customer satisfaction.</p><p dir="ltr">Non-conformance refers to any deviation from specified design, material, or process requirements during manufacturing. In aerospace, even minor deviations can have far-reaching consequences due to the critical nature of components and systems. The most common sources of non-conformance include:</p><ul><li dir="ltr"><p dir="ltr"><strong>Material Defects</strong>: Impurities or inconsistencies in materials that compromise structural integrity.</p></li><li dir="ltr"><p dir="ltr"><strong>Design Discrepancies:</strong> Errors or misinterpretations in design specifications.</p></li><li dir="ltr"><p dir="ltr"><strong>Process Failures:</strong> Incorrect manufacturing processes or assembly techniques.</p></li><li dir="ltr"><p dir="ltr"><strong>Human Error:</strong> Mistakes during production or quality control.</p></li></ul><p dir="ltr">These issues can cause delays, increase costs, and compromise safety. These are the reasons why reducing non-conformance is essential for maintaining operational excellence. Nowadays, aerospace companies can implement novel and robust production support systems based on <a href="https://protect.checkpoint.com/v2/___https://www.ijraset.com/research-paper/digitization-of-non-conformance-workflows-and-processes-in-aerospace-product___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OmRjNmE6NDc3NjZlNjhlZWNjYmYxNzg2MTVhNjczYzgxNzFmMDc0MWZjZDhmYTE3MzliNzJjODYyODcwNzQ5NmQ5NmU4OTpwOlQ6Tg">digital thread technologies</a> in order to significantly reduce non-conformance rates, streamline operations, and achieve higher levels of performance.</p><h2 dir="ltr"><strong>Leading the Way in Digital Thread and Production Support</strong></h2><p dir="ltr" id="isPasted">One of best ways to explore how aerospace manufacturers can leverage digital thread technologies to address these challenges is through a practical approach based on real life case studies. <a href="https://protect.checkpoint.com/v2/___https://www.quest-global.com/___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OmM2MWU6ZjRjZDNkY2QwNjQ2M2ZkNDJhNzlhNzJlZTg5YWMzYTNlMTRiMmFhOGJlOGFhYmMwODJjYTE4MmI5MDgzYTMyODpwOlQ6Tg">Quest Global</a>, a global leader in aerospace production engineering and manufacturing solutions, employs some of the most prominent strategies for reducing non-conformance in the scope of real-life case studies.&nbsp;</p><p dir="ltr">These solutions rely on a communication framework that integrates data across the entire lifecycle of a product. This approach ensures real-time tracking of parts and processes, which enables manufacturers to quickly identify and resolve non-conformances before they escalate into larger problems.</p><p dir="ltr">Quest Global’s approach combines production support with digital thread technologies to optimize flow line operations. The company deploys dedicated cross-functional teams to manage the overall operations and flowlines . In this way, Quest Global ensures that all aspects of production are effectively managed. Thanks to the digital thread approach, the company provides enhanced real-time visibility into key performance indicators (KPIs) while at the same time enabling faster decision-making and improved traceability across the supply chain.</p><h2 dir="ltr"><strong>Real-World Applications: Improving Non-Conformance through Production Support and Flow-Line Efficiency</strong></h2><p dir="ltr">Quest Global has recently implemented a novel production support and flow line efficiency solution for a leading aerospace manufacturer. The manufacturer was struggling with high non-conformance rates due to inconsistent production processes and a lack of real-time data visibility. These issues led to delays in production schedules and increased significantly the costs associated with rework and scrap. Moreover, the aerospace company needed on-the-ground support to manage both internal and external supply chains. This required close collaboration with suppliers and internal teams to ensure smooth operations and timely delivery of components. Also, the customer needed to consult with engineering specialists within their organization to address complex technical issues as they arose.</p><h3 dir="ltr"><strong>Solution Overview</strong></h3><p dir="ltr">To address these challenges, Quest Global deployed a dedicated multi-disciplinary team responsible for managing the entire flow line. This included creating data visualization dashboards, which allowed real-time tracking of key performance indicators (KPIs). The solution enabled the identification of bottlenecks and conducted root cause analysis, which led to significant reductions to non-conformance rates and to tangible improvements to the overall production efficiency.&nbsp;</p><h3 dir="ltr"><strong>Production Support and Flow Line Efficiency</strong></h3><p dir="ltr">The solution consists of a production support and a flow line efficiency part. The production support system provided real-time insights into production processes. This helped the manufacturer to gain better control over their operations towards quicker identification of non-conformances and more informed decision-making.</p><p dir="ltr">The flow line efficiency part optimized the customer’s flow lines by introducing data visualization tools. This allowed for better workflow management, reduced bottlenecks, and smoother production processes.&nbsp;</p><p dir="ltr">Based on the deployment and use of digital threads, the flow line efficiency solution managed to improve data accuracy and to minimize manual errors. This reduced non-conformances and enabled more consistent quality control across the production line. A digital control tower was also established to provide real-time monitoring of production lines. This allowed for immediate corrective actions when deviations were detected, which made the production process more agile and responsive.&nbsp;</p><p dir="ltr">Overall, the digitally enabled flow line efficiency solution led to faster production cycles, reduced waste, enhanced quality control measures, and overall operational improvements. Specifically, the Quest Global’s intervention led to tangible improvements of various KPIs:</p><ul><li dir="ltr"><p dir="ltr">Non-conformance rates&nbsp;were reduced by approximately<strong>&nbsp;30% on key products.</strong></p></li><li dir="ltr"><p dir="ltr">Work-in-progress (WIP) was <strong>reduced by 25%,</strong> while backlogs reduced by 65%.</p></li><li dir="ltr"><p dir="ltr">Total Resolution time (TRT) for NC origination improved dramatically, being processed <strong>within one day.</strong></p></li></ul><p dir="ltr">The solution also enabled ongoing awareness of non-conformance Priorities and Root Cause Analysis (RCA), which was important towards identifying patterns and preventing future issues. Based on RCA, Quest Global enabled trend analysis, which helped pinpoint recurring issues and make informed strategic decisions. This improved forecasting and enabled a proactive approach that allowed the team to predict potential NCs and &nbsp;address them before they escalate.</p><p dir="ltr">Moreover, based on the use of data visualization tools &nbsp;the solution enabled the systematic identification and resolution of bottlenecks in the production process. The elimination of bottlenecks led to more efficient operation of the production line, which is characterized by reduced delays and an overall improved process flow.</p><p dir="ltr">Also, the transition from manual whiteboard tracking to a digital system provided real-time visibility into KPIs. Specifically, this enabled stakeholders to monitor progress at a glance, which led to faster decision-making and more efficient operations across the production line.</p><h3 dir="ltr"><strong>Lessons Learnt: Strategies for Reducing Non-Conformance</strong></h3><p dir="ltr">The successful deployment of the digital thread approach highlights several key strategies that aerospace manufacturers can adopt to reduce non-conformance:</p><ul><li dir="ltr"><p dir="ltr"><strong>Root Cause Analysis (RCA)</strong>: RCA boost the identification of the underlying factors that contribute to non-conformances. In this direction, techniques such as <a href="https://protect.checkpoint.com/v2/___https://www.techtarget.com/whatis/definition/fishbone-diagram___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OmZjMGM6MDI2ZDU1Yjk2YjFkNWFiYzc2ODExMWQ0YjRlN2MxMDMxNjc2NjY3NDZiYzdlMjAzYmZhZTgwMDUyMWFiZWM0OTpwOlQ6Tg">fishbone diagrams</a> can be used to investigate issues thoroughly and to prevent recurrence.</p></li><li dir="ltr"><p dir="ltr"><strong>Continuous Improvement Initiatives</strong>: Regular Kaizen workshops focused on process optimization can lead to significant improvements in flow line efficiency. In the scope of the above-described case study, bottlenecks were methodically identified and eliminated through continuous monitoring.</p></li><li dir="ltr"><p dir="ltr"><strong>Supply Chain Collaboration:</strong> The effective management of both internal and external supply chains is critical for reducing delays and ensuring that quality standards are met. Quest Global's on-the-ground support for suppliers helped streamline operations across multiple stakeholders.</p></li><li dir="ltr"><p dir="ltr"><strong>Digital Transformation – Digital Thread Approach:</strong> The adoption of digital thread technology enables real-time monitoring of production processes and facilitates predictive analytics. This improves operational efficiency and reduces the likelihood of defects.</p></li></ul><h3 dir="ltr"><strong>The reduction of non-conformances leads to tangible benefits, including:</strong></h3><ul><li dir="ltr"><strong>Increased Throughput</strong>: With fewer defects and less rework required, production lines can operate more efficiently and achieve faster turnaround times.</li><li dir="ltr"><strong>Cost Savings:</strong> The reduction of scrap rates and of the delays associated with non-conformances leads to significant cost reductions.</li><li dir="ltr"><p dir="ltr"><strong>Improved Quality:&nbsp;</strong>The early identification of quality issues can lead to products meet the highest quality standards, which is one of the top priorities of the aerospace industry.</p></li></ul><h2 dir="ltr">Non-conformance reduction with digital and agile methods</h2><p dir="ltr">In the next few years emerging technologies such as artificial intelligence (AI), predictive analytics, and advanced digital threads will play an increasingly key role in reducing non-conformances. These technologies will enable manufacturers to predict and potentially remedy potential issues before they occur. This will further enhance safety standards, while improving operational agility. Also, the rise of <a href="https://protect.checkpoint.com/v2/___https://www.tudelft.nl/en/stories/articles/a-digital-product-passport-for-a-circular-economy___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzpiZmM1ZWVjYzgyZTIxZmQ0YjViNjI4NzA4Y2JmZTMyMzo2OjdjY2E6ZGJiM2YyNGEyOTFlYzJjMDM1NWY1YTMwMzdlMDU5YTAxZDE3ZDQwMDI1ODc2ZjhmOTkzMjYxODg0MzExODY4OTpwOlQ6Tg">digital product passport</a> technologies will enhance the ability of digital thread solution to provide enhanced real-time visibility on materials, products, and production processes. This enhanced visibility will further enhance the accuracy of aerospace manufacturers’ decisions.</p><p dir="ltr">Quest Global is at the forefront of this transformation. It is already integrating AI-driven predictive analytics into advanced digital thread solutions, in ways that deliver tangible benefits to aerospace enterprises. Quest Global is committed to integrating the most recent Gen AI and digital thread advancements towards reducing downtimes, improve product quality, and drive further efficiency gains.</p><h2 dir="ltr">Towards a digital-first approach in aerospace manufacturing</h2><p dir="ltr">In conclusion, reducing non-conformance is critical for achieving operational excellence in aerospace manufacturing. Quest Global’s combination of production support, flow line optimization, and digital thread technologies provides a practical solution for addressing these challenges. The implementation of real-time data visibility tools has led to significant improvements in workflow efficiency, reduced bottlenecks, enhanced quality control measures, and lower non-conformance rates.</p><p dir="ltr" id="isPasted">Most aerospace manufacturers are on this journey to &nbsp;adopt such digital-first approaches to improve their overall productivity and profitability, while at the same time meeting stringent regulatory requirements</p><h2>References</h2><p>1. &nbsp;Ubacht J. A digital product passport for a circular economy. TU Delft Stories. 2023 [cited 2024 Nov 10]. Available from: https://www.tudelft.nl/en/stories/articles/a-digital-product-passport-for-a-circular-economy</p><p>2. Gopi S, Joshua DR, Valluri VS. Digitization of non-conformance workflows and processes in aerospace product lifecycle management. Int J Res Appl Sci Eng Technol. 2022.</p><p>3. Pop GI, Titu AM, Pop AB. Enhancing aerospace industry efficiency and sustainability: process integration and quality management in the context of Industry 4.0. Sustainability. 2023;15:16206. doi:10.3390/su152316206.</p>

The aerospace industry faces non-conformances like material defects and process errors, causing delays and safety risks. Digital thread technologies help streamline operations, reduce non-conformances, and ensure adherence to strict quality and safety standards.

Achieving Operational Excellence in Aerospace Manufacturing: Reducing Non-Conformance with Production Support and Digital Threads

<p dir="ltr" id="isPasted">The 23rd edition of the Precision Fair, held at Brabanthallen in 's-Hertogenbosch, has once again positioned itself as the pinnacle event for the high and ultra-precision technology sectors. This year,&nbsp;375 exhibitors&nbsp;and experts from international companies, research institutions, and academia gathered to push the boundaries of precision engineering. The event was enriched with 50 inspirational sessions delivered by industry leaders and innovators, encompassing a diverse range of topics from mechatronic systems to micro processing and motion.</p><p dir="ltr">The fair not only facilitated a networking arena for professionals but also hosted the prestigious DSPE awards, celebrating significant achievements in the field. Additionally, this year marked the introduction of the International Precision Conference, further highlighting the event’s dedication to fostering global collaboration in pursuing technological advancements.</p><p dir="ltr">By bringing together the best of industry and academia, the Precision Fair continues to be a critical hub for sharing knowledge and shaping the future of precision technology.</p><p dir="ltr">Wevolver attended the fair and spoke with a few of the innovative exhibitors.&nbsp;</p><h2 dir="ltr">Hexagon: Enhancing Engineering Processes&nbsp;</h2><p dir="ltr">At the Precision Fair, Hexagon showcased its comprehensive approach to streamlining product development and manufacturing processes with advanced hardware and software solutions. Faruk Pehlivan, representing Hexagon, extended an invitation to their upcoming event,<a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven">&nbsp;Hexagon LIVE Eindhoven</a>, highlighting their commitment to technological innovation.</p><p dir="ltr">Hexagon's solutions facilitate various stages of product development, from CFD analysis to optimise design functionality to G-code preparation for precise manufacturing execution. The standout at the event was their new MarvellScan, an optical scanning device designed for detailed quality checks and reverse engineering. This scanner is distinguished by its autonomous control, flexible movement capabilities, and wireless functionality, making it ideal for ensuring product quality directly against CAD models and enhancing legacy parts through reverse engineering.</p><p dir="ltr">These innovations underscore Hexagon's leadership in integrating technology that enhances production efficiency and product reliability, setting a high standard for quality assurance in manufacturing.</p><p dir="ltr"><a href="https://www.wevolver.com/article/harnessing-manufacturing-intelligence-to-enhance-operational-excellence-in-aerospace">Read more about Hexagon here.&nbsp;</a></p><h2 dir="ltr">Muon Group: Creating microstructures in glass</h2><p dir="ltr">Muon Group, through its member LouwersHanique, showcased its cutting-edge technology for creating microstructures in glass at the Precision Fair. Their process involves a two-step method using femtosecond laser technology. Initially, the glass is precisely modified by the laser, which changes its internal structure. This modification is followed by wet chemical etching, selectively removing the altered glass to create intricate 3D microstructures.</p><p dir="ltr">This technique achieves remarkable precision, allowing for features as small as 1 µm, with tolerances and surface smoothness ideal for specialised industrial applications. Muon Group’s process supports various glass materials like fused silica, sapphire, and borosilicate, catering to a wide range of industries requiring high-precision glass components. Their full suite of capabilities includes not only microfabrication but also complementary services such as optical assembly, CNC milling, and cleanroom packaging, underscoring their comprehensive approach to high-tech glass manufacturing.</p><h2 dir="ltr">Versatile, agile and efficient: Maxon's SCARA Robotics Innovations at the Precision Fair</h2><p dir="ltr">Maxon showcased its innovative solutions for SCARA robots at the Precision Fair, featuring a holistic approach that optimises robotic motion and design for enhanced efficiency. Representatives Francis De Wilde and Mark van Zutphen introduced a full setup including a driver and a hollow-axis motor which allows for efficient cable management and increased space-saving on production lines. Their specialised programming facilitates dynamic flipping motions between work areas, improving pick-and-place operations. Maxon's focus on compact design and powerful performance optimises the use of space and resources in industrial settings, with future goals aimed at increasing the versatility and speed of robotic arms.&nbsp;</p><h2 dir="ltr">New era in precise inspection launched by ZEISS</h2><p dir="ltr">ZEISS launched the O-INSPECT Duo at the Precision Fair, introducing a large-scale measuring machine capable of inspecting items like circuit boards and batteries with optical, tactile, and microscopic methods. This innovation addresses the challenges of measuring large objects without cutting them, offering rapid and precise analysis. The system utilises ZEISS's established metrology and analysis software, and was showcased with demonstrations at the event, underscoring its potential to streamline quality control processes in manufacturing.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731678709332-ZEISS-lanceert-nieuwe-O-INSPECT.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 dir="ltr">Innovative Duo Wins Prestigious Wim van der Hoek Award at Precision Fair</h2><p dir="ltr">The Wim van der Hoek Award, also known as the Constructors Award, was presented during the 22nd Precision Fair. For the first time, the award was given to a duo, Marc Slob and Youp Verbakel, for their innovative design of a machine for automatic assembly of shovels and spades. Their project, which originated from Avans University of Applied Sciences, excelled in terms of design freedom, cost considerations, and production reliability, earning them this prestigious accolade in mechanical engineering design.</p><p dir="ltr">For more details, you can visit the<a href="https://www.dspe.nl/awards/wim-van-der-hoek-award/">&nbsp;DSPE website</a>.</p><h2 dir="ltr" id="isPasted">Liquid hydrogen-powered retrofit aircraft wins Young Talent Award</h2><p dir="ltr">On the inaugural day of the fair, student teams from the nation's top three technical universities competed in the Young Talent Pitch Award, presenting their innovative projects to a panel. The entries included diverse technologies ranging from autonomous racing cars and electric motors to hydrogen-fueled aircraft, a rover designed for the South Pole, and an actual rocket. The competition, which judged entries based on their technical feasibility, social impact, and creativity, concluded with Team Aero Delft claiming the top spot, followed by DARE - Stratos V from Delft in second place.</p><p dir="ltr">Aero Delft is pioneering a transformative approach in aviation with its development of a liquid hydrogen-powered retrofit aircraft. The team is committed to advancing hydrogen propulsion technologies, planning a shift from gaseous to liquid hydrogen to drastically reduce aviation emissions. The jury lauded Aero Delft for their project's technical feasibility and innovative approach, highlighting it as a significant stride towards sustainable aviation. Koen Pijnacker's compelling pitch further solidified their standout status in the competition.</p><p dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731678583425-54141210051_2ddebb5594_c.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2 dir="ltr" id="isPasted">Looking Ahead to 2025 and beyond</h2><p dir="ltr">The fair not only provided a platform for these technological showcases but also set the stage for future collaborations and innovations. Each presentation underscored the industry's focus on enhancing precision and efficiency, driving the boundaries of what's possible in technology and manufacturing.</p><p dir="ltr">The next edition will take place on 12th&nbsp;and 13th&nbsp;November 2025.&nbsp;For more details on the event and future plans, visit<a href="https://mikrocentrum.nl/en/precision-technology/overview-precision-fair/">&nbsp;Mikrocentrum's Precision Fair</a>.</p>

The 23rd Precision Fair showcased innovations like Hexagon's MarvellScan and Maxon's SCARA robots, with Aero Delft winning the Young Talent Pitch for their hydrogen aircraft.


Precision in Practice: Highlights from the 23rd Precision Fair

<p dir="ltr" id="isPasted">Precision, efficiency, and adaptability have always been essential in aerospace manufacturing. Today, simulations, digital twin technology, and real-time monitoring are not only helping companies meet these goals but also bringing them closer to carbon neutrality.</p><p dir="ltr">To drive these innovations, companies require insights into every aspect of the manufacturing process. This is where Hexagon steps in, offering end-to-end workflow solutions to tackle key challenges across design, production, and quality control, with sustainability at the forefront.</p><h2 dir="ltr">Current Challenges and Opportunities in Aerospace Manufacturing</h2><p dir="ltr">Aerospace manufacturers face the challenge of creating complex parts while adhering to strict regulations. Additionally, they aim to reduce waste as part of their sustainability goals. To meet these demands, the industry requires advanced, integrated solutions to streamline production.</p><h3 dir="ltr">Design and engineering</h3><p dir="ltr">In aerospace design, simulations allow engineers to test for safety and performance without the repeated need for prototypes. This not only reduces costs but also makes the development process significantly less wasteful.&nbsp;</p><p dir="ltr">However, running complex simulations requires powerful computing infrastructure. Without the right infrastructure and expertise, many design teams still rely on the more costly approach of prototype testing. This often leads to delays and added expenses in the development cycle.</p><h3 dir="ltr">Production</h3><p dir="ltr">One of the most prominent challenges is long setup times. Aerospace manufacturing involves intricate parts with each production run often requiring recalibrations and adjustments. Machine breakdowns is another well-known issue that can disrupt production.</p><p dir="ltr">Additionally, maintaining consistent quality across multiple production sites is also a hurdle. Due to strict safety standards in aerospace, even minor deviations lead to additional quality checks, which can further slow down production. The industry also faces a shortage of skilled labor.</p><h3 dir="ltr">Quality control</h3><p dir="ltr">Coordinate Measuring Machines (CMM) are crucial for checking the accuracy of aerospace components.&nbsp;However, this process can be time-consuming, especially considering that parts need to be brought to these machines and may require multiple passes. The lack of real-time insights adds to this issue. Without immediate access to measurement data, it becomes challenging for engineers and technicians to detect and address deviations in production early on.</p><h2 dir="ltr">Manufacturing Made Intelligent&nbsp;</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731924823927-Hexagon_MI_OPTIV_M_Multisensor_CMMs_Family_1_Product_Photo_1680x885px.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Hexagon's Multisensor CMMs Family use tactile probing and the high-speed measuring point capture of non-contact measurement on a single system and within a single measurement run for more efficient measurement of complex parts.</span></span></span></p><p dir="ltr">Hexagon is a global leader in digital reality solutions, offering integrated manufacturing intelligence that spans from design to final product. The company’s goal is to make advanced technology accessible on the shop floor to ensure consistent quality throughout the process. Hexagon has supported top brands and organizations, including Formula 1’s Red Bull Racing, the cutting-edge research of CERN, and automotive giant Volkswagen. Its core offerings are as follows:</p><h3 dir="ltr">Complete integration</h3><p dir="ltr">Hexagon provides comprehensive integration across the entire aerospace production cycle, spanning design, manufacturing, and quality control. This seamless integration allows data to move freely across each stage and system, creating transparency that enables stakeholders to monitor progress at every step. With actionable insights coming from each phase, aerospace teams can make the right decisions that improve overall efficiency and product quality.</p><h3 dir="ltr">Simulation and optimization</h3><p dir="ltr">Hexagon’s Computational Fluid Dynamics (CFD) solutions help aerospace engineers simulate and analyze the aerodynamic forces acting on aircraft components. This allows companies to fine-tune designs without the need for physical prototypes at each iteration. Furthermore, Hexagon's data-driven approach enables teams to pinpoint bottlenecks and improve process efficiency, which leads to more sustainable production.</p><h3 dir="ltr">Real-time monitoring</h3><p dir="ltr">Hexagon’s real-time monitoring solutions bring machine and production data directly to engineers and operators through easy-to-read dashboards.&nbsp;This real-time accessibility enables better communication and collaboration between teams, while continuous monitoring enables predictive maintenance, reducing downtime by identifying potential issues before they escalate.</p><h2 dir="ltr">Ensuring Smart Design, Intelligent Production and Integrated Quality Assurance</h2><h3 dir="ltr">Smart Design for Aerospace Engineering</h3><p dir="ltr">Hexagon offers a cloud-based simulation tool Nexus Compute. Supporting various technologies including scFLOW, it enables engineers to test their designs for aerodynamic stress including hypersonic conditions. The cloud-based nature of the tool ensures that stakeholders from different teams can collaborate seamlessly. Hexagon's solutions also come with Integrated Computational Materials Engineering (ICME) for virtual material testing.</p><h3 dir="ltr">Intelligent Production for First-Time-Right Manufacturing</h3><p dir="ltr">Hexagon’s real-time monitoring solutions provide manufacturers with continuous insights into workflow efficiency, enabling engineers to catch potential issues before they lead to costly delays.</p><p dir="ltr">With digital twin technology, Hexagon takes monitoring to another level by creating virtual replicas of physical equipment.&nbsp;It gives manufacturers a real-time view of machinery performance and its wear patterns paving the way for predictive maintenance.</p><h3 dir="ltr">Integrated Quality Assurance</h3><p dir="ltr">Hexagon offers in-process measurement, a system that measures and monitors parts or components during production. By integrating measurement tools directly into the production stage, manufacturers can detect and address defects early in the cycle, significantly reducing waste.</p><p dir="ltr">Hexagon’s centralized data and documentation platform also ensures that information is easily accessible across teams. This facilitates traceability and better decision-making across the shop floor. Additionally, this approach streamlines processes for regulatory compliance and supports consistent quality across operations.</p><h2 dir="ltr">Real-World Application: Aeroplane Wing Nose Rib Case Study</h2><p dir="ltr">The aeroplane wing nose rib is a critical structural element that withstands intense aerodynamic forces while maintaining minimal weight. Getting it right with traditional methods is a time-consuming affair. However, with its end-to-end workflow solutions, Hexagon helped the client optimize every stage of the production cycle. Let’s find out how its advanced manufacturing intelligence helped streamline operations, reduce costs, and minimize waste to support sustainability.</p><h3 dir="ltr">Design Optimization</h3><p dir="ltr">Using Hexagon’s CFD and system dynamics, the team tested their designs in high-speed flow simulations. Through tools such as scFLOW, engineers were able to simulate high-speed flow conditions, including extreme phenomena like shockwaves. This virtual testing accurately gauged load behaviors and aerodynamic stresses, allowing engineers to evaluate multiple configurations and zero in on the one that meets stringent performance requirements before moving on to the prototyping phase.</p><h3 dir="ltr">Manufacturing Preparation and Verification</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxNTc1NTY3MjU4LWhleGFnb24tbm9zZS1yaWItLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr">In preparation for manufacturing, the client used Hexagon's digital twin technology to ensure precise alignment between design specifications and production processes. Through CAD modeling and direct "Send To CAM" interoperability, engineers ensured compatibility between design and manufacturability. Digital twins allowed for accurate simulation of material and process interactions, ensuring that each step adhered to high-quality standards with minimal operator intervention.</p><h3 dir="ltr">Shop-Floor Operations and Quality Inspection</h3><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxNTc1NjA5MjQyLWhleGFnb24td2luZy1ub3NlLXJpYi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr">With in-machine measurement solutions and portable machines ready for the shop floor, the team was able to collect measurement data without delays. Hexagon's first-time-right machining approach minimized revisions and significantly reduced material waste. Hexagon’s in-machine inspection capabilities enabled real-time measurement of components, ensuring adherence to design tolerances. The integration of CMM allowed the client to capture high-precision measurements for geometric and free-form features. Portable machines equipped with various high-speed sensors enabled continuous quality assurance, minimizing waste and accelerating the process.</p><h3 dir="ltr">Reporting and Analytics</h3><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxNTc1NjUwOTc4LWhleGFnb24tdXNlci1zdG9yeS1xdWFsaXR5LWluc3BlY3Rpb24uanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">The team had easy access to real-time sensor data through Hexagon’s reporting tools. By centralizing all relevant documentation in the cloud, these tools made it easy for engineers and management to review process metrics and identify areas for improvement in both design and manufacturing. The digital records supported regulatory compliance with aerospace industry standards, which effectively reduced time spent on audits.</p><h2 dir="ltr">Key Benefits of Manufacturing Intelligence:</h2><ul><li dir="ltr"><p dir="ltr">With its digital twins, simulation, and optimized workflows, Hexagon can help aerospace manufacturers accelerate product development. In the past, its clients have achieved up to a 30% reduction in time from concept to production.</p></li><li dir="ltr"><p dir="ltr">With Hexagon’s virtual testing tools, the need for physical prototypes is minimized. This can mean up to a 50% reduction in cost for aerospace companies compared to traditional methods.</p></li><li dir="ltr"><p dir="ltr">The company’s manufacturing intelligence solutions can improve “first-time-right” production rates. This reduces the need for rework saving time and resources.</p></li><li dir="ltr"><p dir="ltr">Through real-time monitoring and predictive maintenance, Hexagon maximizes machine uptime and productivity.</p></li><li dir="ltr"><p dir="ltr">A focus on quality control means Hexagon’s solutions help manufacturers comply with industry standards more reliably while also supporting sustainability by reducing waste.</p></li><li dir="ltr"><p dir="ltr">Digital documentation offers complete traceability across the product lifecycle. This ensures compliance with regulatory requirements and industry standards with more confidence.</p></li></ul><p dir="ltr">The aerospace industry faces complex challenges in various production stages. For instance, access to advanced simulation tools is often limited. On the production floor, long setup times are common, and maintaining consistent quality across facilities is a struggle. Precision measurements CMMs is crucial but can often become bottlenecks in the workflow.</p><h2 dir="ltr">Step into the Manufacturing of Tomorrow at Hexagon LIVE</h2><p dir="ltr">Hexagon’s manufacturing intelligence suite addresses these challenges with its end-to-end solutions. Their cloud-based simulation tools enable engineers to run essential design tests faster and more collaboratively. By providing real-time monitoring throughout production, Hexagon helps manufacturers achieve consistent quality and reduce waste. Additionally, Hexagon speeds up the traditionally slow CMM measurement process by integrating measurement tools directly into the production stage.</p><p dir="ltr">Curious about how Hexagon's manufacturing intelligence can transform your organization? Join the Hexagon LIVE event in Eindhoven on <strong>November 27</strong> to explore their digital solutions firsthand.</p><p dir="ltr">Don’t miss this opportunity to connect with industry experts, explore the latest innovations, and get your questions answered by Hexagon specialists.</p><p>Secure your spot today!</p><p><a href="https://events.hexagon.com/Hexagon_LIVE_Eindhoven?creative=713450062%20759&keyword=hexagon%20live%20eindhoven&matchtype=e&network=g&de%20vice=c&gad_source=1&gclid=Cj0KCQjw99e4BhDiARIsAISE7P-jq9--%20x4A0TeKGXvQPXSR46iJ28I8bV7tNL3-yyfjZcLlvv_LBpE4aAsuEEALw_wcB" target="_blank" rel="noopener noreferrer" class="button-main-action">Read more and register</a></p>

Explore how advanced solutions in manufacturing intelligence are transforming aerospace manufacturing by addressing key challenges in design, production, and quality control while promoting sustainability. 

Harnessing Manufacturing Intelligence to Enhance Operational Excellence in Aerospace

<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">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 dir="ltr">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">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

<h3 id="isPasted">Rooster Drone: Revolutionizing Search-and-Rescue and Tactical Operations</h3><p>In the ever-evolving field of unmanned aerial vehicles (UAVs), the Rooster drone by Robotican stands out as a groundbreaking solution for search-and-rescue, tactical, and security operations. Engineered to be an agile, resilient, and intelligent UAV, the Rooster drone’s core capabilities enable it to perform in high-risk environments, making it an invaluable asset for defense forces and emergency response teams worldwide. Let's dive into the technical specifications and capabilities that make this drone a true innovation.</p><h4>Flight In Complex Environments</h4><p>Built to operate in GPS-denied environments. This system is particularly advantageous in environments with compromised visibility or structural instability, such as collapsed buildings or booby-trapped spaces.</p><p>The Rooster’s AI-driven algorithms enable it to dynamically adapt to changing environments, This capability allows the Rooster to minimize risks to personnel, providing crucial data in situations where human entry would be too dangerous.</p><h4>Durable Design and Resilience</h4><p>Designed with operational durability in mind, the Rooster drone’s rugged frame and flexible, shock-absorbent materials give it the resilience needed for both indoor and outdoor operations. Unlike conventional drones that may be vulnerable in confined spaces, the Rooster’s robust body structure and flexible propeller guards ensure it can recover quickly after minor collisions, allowing it to continue its mission uninterrupted.</p><p>Additionally, the Rooster’s compact design enables it to enter narrow passageways and navigate tight spaces—a significant advantage in scenarios where traditional, larger drones would be hindered.<br><br><br><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731312571642-Rooster+for+article.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h4>Real-Time Data Transmission and Advanced Sensing Capabilities</h4><p>Equipped with high-definition cameras, thermal imaging, and variable sensors the Rooster is capable of delivering real-time visual and thermal data to operators on the ground. This multi-sensory data provides a comprehensive view of the operational environment, enabling better decision-making under high-pressure situations. Those features are particularly useful for operations in dimly lit or smoke-filled rooms where visibility is otherwise compromised.</p><h4>Simplified User Interface and Intuitive Control</h4><p>Robotican has designed the Rooster with an intuitive user interface that simplifies control for operators with varied technical backgrounds. The system’s interface can be accessed on standard tablets or laptops, providing a real-time, high-definition feed and mission controls. Operators can quickly command the drone with straightforward commands or set it on an autonomous route using its way-point navigation system.<br><br><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731313531966-For+article.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p>For defense applications, this ease of use translates to faster deployment and reduced training time. The Rooster’s controls are designed to be highly responsive, making it a powerful tool in fast-paced tactical scenarios where every second counts.</p><h4>Compact and Ready for Rapid Deployment</h4><p>The Rooster drone’s portability and readiness make it an ideal solution for situations requiring rapid deployment. With a fast setup time, it can be operational within minutes, significantly reducing the time between arrival on the scene and the commencement of the mission.</p><p>Weighing under a few kilograms, the Rooster is compact enough to be carried in a backpack and deployed by a single operator. This lightweight design, combined with its modularity, allows for easy transport and swift adjustments based on mission requirements.</p><h4>Applications Across Diverse Operational Needs</h4><p>The versatility of the Rooster drone allows it to support a wide range of operations. From search-and-rescue missions in disaster-stricken areas to surveillance tasks in military and police operations, its capabilities serve as a force multiplier for teams in the field. In recent military applications, the Rooster has demonstrated its unique ability to identify threats, such as detecting improvised explosive devices (IEDs) in potentially hostile environments, saving lives and improving operational outcomes.</p><p>Its usage has also extended to various emergency services, with fire departments and other first responders deploying the Rooster in challenging situations where human lives are at risk. The drone’s ability to rapidly scan a building for survivors or detect hotspots in a fire scenario has proven invaluable, showcasing its adaptability and life-saving potential.</p><h4>Conclusion</h4><p>The Rooster drone by Robotican exemplifies the future of autonomous drones in high-stakes environments. Its combination of autonomous navigation, durability, advanced sensing, and rapid deployment capabilities equips it to handle the complexities of modern tactical, rescue, and surveillance operations. Whether deployed by defense forces or emergency responders, the Rooster is setting new standards for UAV performance, reliability, and mission success.</p><p>As the demand for resilient, autonomous solutions grows, the Rooster drone is poised to become an essential asset in the operational toolkit of those on the frontlines, pushing the boundaries of what is possible with unmanned aerial technology.</p>

A Hybrid Robotic Drone Engineered for Precision and Resilience in High-Stakes Tactical and Search-and-Rescue Operation

Rooster Drone: Revolutionizing Search-and-Rescue and Tactical Operations

<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">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 dir="ltr">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">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">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">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">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">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">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">Space deployment comes with a series of significant engineering challenges for the electronic and electrical systems that are going to be utilised. Engineers must therefore specify components for their designs that have all the necessary properties – particularly in relation to coping with the harsh environments they are going to be situated in, alongside the acute size, weight and power (SWAP) constraints involved. In this article, we will look at exactly what this will entail and give a detailed use case example to illustrate the points raised too.</p><h2 dir="ltr">Unique aspects of the application setting</h2><p dir="ltr">Though this must still be adequately addressed, it is not actually space itself that poses the biggest threat to component reliability. Instead, it is the process of getting it there that is likely to be the problematic part. During launch, a rocket’s payload can easily be subjected to 4-5g accelerations. On top of that, there are certain to be intense vibrational forces experienced. There is the potential for hardware to be exposed to very high levels of heat too. Should any damage occur at this stage, then the space deployed equipment might not be able to carry out its assigned functions as intended and the mission will end up being a failure.&nbsp;</p><p dir="ltr">Once the hardware is finally in orbit, there will be other considerations. Among the most prominent is the temperature cycling that components will have to deal with – going from severe cold when traversing the dark side of the Earth, followed by periods in the Sun’s harsh thermal radiation. Another consideration is whether the chosen components will be detrimentally affected by the vacuum of space. Outgassing means that chemical substances could be emitted from these components, due to seepage from cracks or internal gaps. This might result in delicate instrumentation in close proximity to them being impaired in some way by the presence of unwanted contaminants. Once again, the mission could be jeopardised, meaning that all the expense and engineering effort that had gone into it would count for nothing. &nbsp;&nbsp;</p><h2 dir="ltr">Sourcing interconnects for space&nbsp;</h2><p dir="ltr">The various factors just described make it very clear that the connectors and cabling being selected for space deployment must have superior operational characteristics. Consequently, it is vital that they are able to withstand prolonged mechanical stresses (in terms of both shock and vibration), as well as extreme temperatures. The remote nature of the application of course means that once deployed there is no opportunity to replace faulty interconnects. This is why chances cannot be taken on choosing anything other than a solution with the highest degrees of reliability and resilience to the most challenging of ambient environments.</p><p dir="ltr">Having collaborated on a multitude of different projects in this sector over several decades, Harwin offers an extensive portfolio of space-qualified connectors and cables. Each of these has a heavy duty construction, so that prolonged reliability is assured. They can be provided with built-in shielding (both backshells and braids) to protect them from cosmic radiation.</p><h3 dir="ltr">Use case example</h3><p dir="ltr">A recent venture, on which Harwin worked with the Group of Astrodynamics for the Use of Space Systems&nbsp;(GAUSS), underlines the need for sourcing appropriate connectors and cabling. GAUSS is an established provider of microsatellite deployment solutions, as well as designing and manufacturing its own satellite hardware. The Italian company’s UNISAT platform enables the in-orbit-release of third-party pico/nano-satellites, with numerous CubeSats and PocketQubes being carried into space on each mission and then getting deployed directly from a purpose-built spacecraft. This approach has made it much more convenient and cost-effective for academic research groups to undertake space-based experiments and monitoring work, as they can reduce the upfront expense normally associated with ‘rideshare’ activities.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729852467851-wendy-1.jpg" style="width: 832px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 1: The UNISAT-7 pico/nano-satellite deployment platform from GAUSS (images courtesy of Gauss Srl)</span></span></span></p><p dir="ltr">When the GAUSS team embarked upon the development of their latest UNISAT spacecraft, there were some key objectives that they wanted to achieve. The most important of these was to be able to expand the payload capacity. This would mean that a greater quantity of CubeSats and PocketQubes could be deployed. The engineering team at GAUSS looked at ways that they could make UNISAT-7 construction more lightweight than the previous models, so more of the assigned launch mass could be taken up by the payload.&nbsp;</p><p dir="ltr">For it to be accommodated in the rocket, the UNISAT-7 spacecraft’s overall volume had to be kept as low as possible. Its total launch mass had to be kept down to no more than 32kg. All of the constituent electronics would be contained within an aerospace-grade aluminium honeycomb framework of 50mm x 50mm x 50mm dimensions. This would have carbon fibre sheets attached to it. The spacecraft’s power would be generated by banks of photovoltaic panels mounted onto its exterior.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729852521555-wendy+3.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 2: View of rocket used to deploy multiple satellites (image courtesy of GK Launch Services)</span></span></span></p><p dir="ltr">Given that the UNISAT-7 needed to remain operational for up to 5 years, the ongoing integrity of the interconnect technology had to be beyond doubt. After sampling and testing connectors from a variety of different manufacturers, GAUSS engineers decided that going with units featured in the Harwin Datamate series would be the best tactic. Datamate and Datamate Mix-Tek connectors have shown themselves to be very effective when used in spaceborne equipment. These high-reliability (Hi-Rel) components are robust enough to cope with the difficult conditions posed by space launches. They can withstand 20G vibrations and 100G shocks, plus up to 125°C temperature levels. Their compact form factor means that they take up only minimal board space, leaving plenty of room for other devices.</p><p>The 4-finger Beryllium Copper contacts incorporated into Harwin Datamate connectors allow them to always maintain a connection with their corresponding mating surfaces. The contacts in a standard Datamate mating pair carry up to 3A of current, while Datamate Mix-Tek contacts are 40A rated. The advanced locking features employed mean that industry-leading interconnect retention is attained.</p><p>The low outgassing that these connectors exhibit is another important benefit. For instance, the moulded plastic used in them has a 1.01% total mass loss (TML) and a collected volatile condensable material (CVCM) figure of less than 0.01% when placed in the vacuum of space.</p><p dir="ltr">Complementing their low profile, the availability of right-angle configuration Datamate versions addresses limited gaps between PCBs in space hardware designs. It means that connectors can be positioned at the edge of these PCBs, thereby avoiding the need for cabling to reach further into these boards. The upshot is that cables and connectors are much easier to access when the hardware is being assembled. Furthermore, cables do not need to be bent to such great angles – with less chance of them breaking in the process. &nbsp;</p><p>Having been successfully trialled out by GAUSS, the selected Harwin connectors would play an integral role in the communication and data processing elements of the UNISAT-7, allowing all the related data to be transported. They would also prove essential to the spacecraft’s power systems.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729852579004-wendy+4.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 3: Connectors visible in the PCB stack of a small satellite (image courtesy of Gauss Srl)</span></span></span></p><h2>Conclusion</h2><p dir="ltr">Space hardware must be able to rely on the quality of interconnect technology that has been specified for it. Any cutting of corners here could lead to projects that may have taken years to prepare for and large amounts of money to fund falling short of the goals that they were originally set and not meeting expectations. That is why engaging with an expert in this area is definitely advised. This will mean the connectors and cabling can be recommended that are fully optimised for such purposes.</p>

Space deployment presents significant engineering challenges for electronic and electrical systems, requiring engineers to specify components with properties suited to harsh environments and acute size, weight, and power (SWAP) constraints.

Implementing Effective Interconnects into Space System Designs

<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><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243114034803343" title="Quest Global Form [Webinar 1]" allowtransparency="true" src="https://form.jotform.com/243114034803343" frameborder="0" style="min-width:100%;max-width:100%;height:1230px;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><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><p dir="ltr"><a href="https://form.jotform.com/243114034803343" target="_blank" rel="noopener noreferrer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5NjAxNjA2NDQyLTUgKDEpLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></a></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><br></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&nbsp;<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">New Webinar: Unlocking the Potential of Digital Twins for Aerospace Manufacturing</h2><p>Register for Quest Global’s upcoming webinar “Unlocking the Potential of Digital Twins for Aerospace Manufacturing” on December 12th to learn more about how Quest Global provides digital engineering solutions to the aerospace industry, gain key insights, engage with industry experts, and ask questions.</p><p><a href="https://form.jotform.com/243114034803343" target="_blank" rel="noopener noreferrer" class="button-main-action">register here</a></p><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

<div data-message-author-role="assistant" data-message-id="678dcb21-279e-4b73-b592-a9c0fa9c4417" dir="auto" data-message-model-slug="gpt-4o" id="isPasted"><p>The aerospace industry faces growing challenges, from managing complex supply chains and rising operational costs to meeting stringent regulatory demands—all while striving for greater safety, efficiency, and cost reduction. Traditional methods are falling behind, resulting in lengthy design cycles, costly prototyping, and interoperability issues. To stay competitive, companies are increasingly adopting digital twin and digital thread technologies to drive innovation and operational excellence.&nbsp;</p><p>In the new webinar "<strong>Unlocking the Power of Digital Twins for Aerospace Manufacturing,</strong>" Quest Global, with over two decades of experience in digital transformation of both aerospace and defense manufacturing, will share expert insights on how these technologies are transforming the industry. By attending you will learn actionable strategies to integrate these cutting-edge tools into your own processes, enabling faster design cycles, smarter production methods, and enhanced regulatory compliance. Don't miss this unique opportunity to learn from Quest Global’s real-world success stories and drive your operational success:</p></div><h3 dir="ltr" id="isPasted">Event Details:</h3><ul><li dir="ltr"><h3><p dir="ltr">Topic: Unlocking the Potential of Digital Twins for Aerospace Manufacturing</p></h3></li><li dir="ltr"><p dir="ltr"><strong>Date</strong>: 12th of December 2024</p></li><li dir="ltr"><p dir="ltr"><strong>Time</strong>:&nbsp;8:00 am PDT | 11:00 am EDT | 17:00 CEST</p></li><li dir="ltr"><p dir="ltr"><strong>Location</strong>: Online (via Zoom).&nbsp;</p></li></ul><p><br></p><p dir="ltr"><br></p><div data-message-author-role="assistant" data-message-id="dcaa0b5a-cf2d-4bc8-bf4c-6561c07f5a4e" dir="auto" data-message-model-slug="gpt-4o" id="isPasted"><h3>Leading the Transformation in Aerospace Innovation: How Quest Global is Revolutionizing Aerospace with Scalable Digital Solutions</h3></div><p dir="ltr">Spearheading this digital transformation across two decades, Quest Global has a proven track-record of successful implementation of scalable digital solutions in the aerospace and defense industry. In this webinar Head of Engineering, Nick Charles and Head of Advanced Manufacturing CoE Vijay Anand, from Quest Global will sit down with tech writer Samir Jaber to unpack how aerospace manufacturers and Original Equipment Manufacturers (OEMs) are leveraging digital twin technology and digital threads to enhance operational efficiency.</p><h3 dir="ltr">Leveraging cutting-edge technology for aerospace manufacturing</h3><p dir="ltr">Join us for an insightful webinar as we explore how&nbsp;digital thread&nbsp;and&nbsp;digital twin&nbsp;capabilities are revolutionizing the Aerospace and Defense (A&amp;D) ecosystem by enabling early identification of design issues, ensuring interoperability and interface verification of parts and systems, and conducting simulations for verification and validation. They also support virtual training, assess maintainability, optimize manufacturing methods, and facilitate the use of Virtual and Smart Factories, ultimately offering a path to increased efficiency and regulatory compliance.</p><p dir="ltr">Discover how these advancements are shaping the future of the industry and driving operational excellence:</p><h3 dir="ltr">Who Should Attend?</h3><p dir="ltr">This webinar is designed to provide <strong>aerospace engineers, manufacturing professionals,</strong> and <strong>decision-makers</strong> looking to optimize their production processes with actionable insights into the transformative power of digital twins. By attending, you'll gain practical knowledge on using digital twin technology to boost efficiency, reduce costs, and improve overall aerospace operations, making it a must-attend event for those looking to stay competitive in the industry.</p><h3 dir="ltr">Why you should attend:</h3><ul><li dir="ltr"><p dir="ltr"><strong>Learn Cutting-Edge Techniques:&nbsp;</strong>Discover how digital twins can transform aerospace manufacturing by reducing non-conformance, improving process efficiency, and optimizing designs with predictive analytics.</p></li><li dir="ltr"><p dir="ltr"><strong>Enhance Decision-Making:</strong> Understand how integrating digital twins into aerospace supply chains enables real-time decision-making for better outcomes and reduced downtime.</p></li><li dir="ltr"><p dir="ltr"><strong>Gain Competitive Advantage:</strong> Stay ahead by learning to leverage digital twins to streamline operations, boost productivity, and drive innovation in the aerospace industry.</p></li></ul><h2 dir="ltr">Explore more details of the webinar below:</h2><p dir="ltr"><strong>Date</strong>: Thursday, December 12, 2024</p><p dir="ltr"><strong>Time</strong>: 8:00 am PDT | 11:00 am EDT | 17:00 CEST</p><p dir="ltr">This webinar will cover how digital twins and digital threads are revolutionizing aerospace manufacturing by bridging the gap between design and production. Nick Charles, Head of Engineering at Quest Global, and Head of Advanced Manufacturing CoE Vijay Anand, will share expert insights on the importance of real-time synchronization and collaboration using these technologies. The session will include a case study demonstrating a successful implementation that led to significant reductions in cycle times and improved efficiency. By attending you will also gain actionable insights on how to begin integrating digital twin and digital thread solutions into their own operations, streamlining processes and fostering innovation.</p><h3 dir="ltr">Key insights include:</h3><ul><li dir="ltr"><p dir="ltr"><strong>Cutting the Design Cycle</strong>: Learn how digital twins help identify design issues early, verify interfaces, and conduct simulations of environmental behaviors and characteristics, drastically reducing design times and errors.</p></li><li dir="ltr"><p dir="ltr"><strong>Optimizing Manufacturing Methods</strong>: Discover how digital twins can improve the design of manufacturing tools and methods, enabling the use of Virtual and Smart Factories to boost production efficiency.</p></li><li dir="ltr"><p dir="ltr"><strong>Enhancing Predictive Maintenance:</strong> Gain insights into how digital twins enable real-time data analytics, helping to predict and prevent failures, extending equipment lifespan, and optimizing operational efficiency.</p></li></ul><h3>Speaker details</h3><table style="width: 100%;"><tbody><tr><td style="width: 50.6024%;"><p id="isPasted"><strong>Nick Charles</strong></p><p>Head of Engineering - UK Defense at Quest Global</p>Nick Charles is the Head of Engineering (UK Defence) at Quest Global and a seasoned engineering leader with extensive experience in the aerospace and defense sectors. Previously, he served as VP and Senior VP at Ultra Maritime, leading a team of over 800 engineers across five countries. Was responsible for challenging engineering projects and drove major improvements in engineering processes, team development, and risk management</td><td style="width: 49.3976%; vertical-align: top; text-align: left;"><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxMzI5NTIwODI1LW5pY2stY2hhcmxlcy1xdWVzdC1nbG9iYWwuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 331px;" class="fr-fic fr-dib"></p></td></tr><tr><td style="width: 50.6024%; vertical-align: top;"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5NTk3MTYxMzY5LVZpamF5LUFuYW5kLVFHLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 315px;" class="fr-fic fr-dib"></td><td style="width: 49.3976%; vertical-align: top;"><p id="isPasted"><strong>Vijay Anand R (VJ)</strong></p><p>GM – Head of Advanced Manufacturing CoE at Quest Global</p>VJ is Head of Advanced Manufacturing CoE of Quest Global based out of Derby, UK.<br>He is a veteran of Manufacturing Engineering for over 30 Years, both with Traditional and Digital manufacturing.<br>He is heavily influenced by Toyota way of working and embraced the same in his roles at Quest Global while managing Global manufacturing team and solutions for major Aerospace &amp; Defense, Energy and Transportation customers till date.<br>He has been instrumental in setting up a Digital Manufacturing Lab in partnership with Siemens to Design, Develop and Simulate the manufacturing and assembly operations. He also represented Quest Global for a Major Aero Engine customer’s Digital Manufacturing Focus Group conferences held at various global locations.</td></tr><tr><td style="width: 50.6024%; vertical-align: top;"><p id="isPasted"><strong>Luke Logan</strong></p>Luke Logan is a seasoned business leader with a significant career in engineering and technology. With 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.<br>Now, as an independent advisor and consultant, Luke applies his extensive experience to support the growth and development of his clients' businesses. He is deeply committed to diversity &amp; inclusion, innovation, and aligning engineering professionalism with business success and sustainability. Luke is a Fellow of The Royal Academy of Engineering, the Institute of Mechanical Engineering, and the Royal Aeronautical Society.<br></td><td style="width: 49.3976%; vertical-align: top;"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTMyMDkwODQ3LUlNR18zNTM4LmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 346px;" class="fr-fic fr-dib"></td></tr></tbody></table><h3>Stay ahead of the curve in aerospace manufacturing</h3><p>Register now to learn how integrating digital twins and digital threads can revolutionize your manufacturing processes, improve collaboration, and maintain competitiveness in the evolving aerospace landscape.</p>

Register for the new webinar with Quest Global to discover how digital twins are revolutionizing aerospace manufacturing by cutting design cycles, driving predictive maintenance, and improving manufacturing efficiency.

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