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CAELESTIS · Project

Digital Twin Ecosystem for Faster Aircraft Design and Defect-Free Manufacturing

transportTestedTRL 4

Imagine having a perfect digital mirror of an airplane part that predicts exactly how it will behave during manufacturing. Instead of building and breaking physical prototypes, engineers use supercomputers to simulate every possible mistake before it happens. It's like having a GPS for the factory floor that tells workers how to fix a part in real-time based on a digital prediction.

By the numbers
12
consortium partners
5,956,880
EU contribution in EUR
42%
industry ratio in consortium
The business problem

What needed solving

Aircraft manufacturers struggle with the gap between design and production, often discovering manufacturing defects too late. This leads to expensive scrap, long redesign cycles, and structural integrity risks.

The solution

What was built

An Interoperable Simulation Ecosystem (ISE) and high-fidelity digital twins. These tools link CAD-CAE software to shop-floor edge devices for real-time defect prediction.

Audience

Who needs this

Aerospace structural engineersComposite materials manufacturing managersDigital twin software architectsQuality assurance leads in aviation
Business applications

Who can put this to work

Aerospace
enterprise
Target: Aircraft Original Equipment Manufacturer (OEM)

If you are an OEM dealing with long design cycles for new engine configurations — this project developed an Interoperable Simulation Ecosystem that accelerates design optimization and ensures parts can actually be built from the start.

Composite Materials
mid-size
Target: Advanced Carbon Fiber Component Supplier

If you are a supplier dealing with curing distortions and voids in automated fibre placement — this project developed high-fidelity digital twins that detect manufacturing flaws and suggest corrective actions to save scrap.

Industrial Software
any
Target: CAD/CAE Software Vendor

If you are a software vendor dealing with fragmented data flow between design and production — this project developed a multidirectional dataflow system that links engineering tools with shop-floor edge computing.

Frequently asked

Quick answers

What is the cost or pricing for implementing this system?

Based on available project data, specific commercial pricing is not listed, though the EU provided a contribution of EUR 5,956,880 for the development phase.

Can this be scaled to full industrial aircraft production?

The project aims for industrial scale by using HPC infrastructures and reduced order models for real-time shopfloor monitoring, though current reports mention activities at a laboratory scale.

How is the IP and licensing handled for the simulation ecosystem?

Based on available project data, the specific licensing terms are not disclosed in the summary; it is managed by a consortium of 12 partners including 5 industry members.

How does this integrate with existing design tools?

It uses an Interoperable Simulation Ecosystem (ISE) designed to link distributed engineering teams' CAD-CAE tools through multidirectional dataflow.

What is the timeline for deployment?

The project period runs from 2022-05-01 to 2025-10-31, with laboratory-scale activities currently nearing completion.

Consortium

Who built it

The consortium is heavily weighted toward industrial application with a 42% industry ratio, comprising 5 companies and 3 SMEs. With 12 partners across 8 countries, the project balances academic research (2 universities, 4 research centers) with practical manufacturing expertise, ensuring the resulting simulation tools are grounded in real-world aircraft production needs.

How to reach the team

Contact ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE for technical inquiries.

Next steps

Talk to the team behind this work.

Contact us to bridge the gap between these laboratory results and your production line.

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