US APAC EUROPE CANADA LATAM
Aerospace and Defense Review

Going Green in Aerospace and Defense with the Grey-to-Green Shift

The aerospace and defence industry is transitioning from an older to a younger workforce, but it faces intense competition for talent. It needs a radical response.

FREMONT, CA: Aerospace businesses heavily rely on maintenance, repair, and overhaul (MRO) to ensure aircraft safety, dependability, and availability. A rise in air traffic and ageing aircraft have led to an increase in the demand for MRO services. 

Data analytics and 3D tools have the potential to revolutionise A&D maintenance in today's rapidly changing digital environment by increasing productivity, lowering costs, boosting safety, and enhancing total equipment reliability. These instruments can aid in determining when maintenance is necessary, allowing maintenance teams to take proactive measures to handle problems before they result in equipment failure. This decreases downtime, boosts the dependability of the machinery, and ultimately saves money. Additionally, 3D visualisation tools can significantly lower the cost of repairs by assisting maintenance teams in visualising and troubleshooting complicated systems in three dimensions. To identify potential safety hazards, departments like engineering and design can collaborate and teach maintenance employees using the tools.

Stay ahead of the industry with exclusive feature stories on the top companies, expert insights and the latest news delivered straight to your inbox. Subscribe today.

Applications with a 3D interface make it easier to describe and simulate a system or subsystem using multiple physics. This aids in determining the maintainability in a 3D context and determining the component's residual life through simulations. Assessing induced structural/thermal stress, fatigue, fracture initiation, etc. is done to achieve this.

It's more evident than ever that legacy aviation maintenance systems are getting older as large data sets continue to be produced quickly from numerous sources. To handle the effects of the data flood and maintain its competitiveness, the Aerospace and Defense sector as a whole must now optimise digital MRO. To connect diverse data and decision-makers, the entire maintenance environment must be connected. To increase fleet availability, lower MRO costs, and maximize fleet safety and sustainability, a completely integrated digital platform with a data-driven model is essential.

Companies in the aerospace and defence industries must now make the transition to a completely integrated digital platform that improves digital MRO collaboration, agility, and efficiency. To unify the ecosystem and collaborate as one, this calls for the use of a single data model and an integrated platform, as well as predictive analytics to cut down on unplanned maintenance, product lifecycle management to increase fleet availability and safety, and virtual twin technology to speed up turnaround times.

Utilising the virtual 3D twin of the selected aircraft system on the 3DEXPERIENCE platform, one can overlay the relevant flying operational data, engineering, and maintenance details. This makes it easier for the MRO team to analyse a system or component rapidly and to take immediate corrective action using the 3DEXPERIENCE platform. This closed-loop method makes it possible to be quicker and more efficient.

Companies need to embrace digital transformation in all facets of their MRO operations and implement a digital-first mentality. This includes utilising cutting-edge technologies to enhance maintenance procedures, boost sustainability, and boost productivity, such as Virtual Twin, artificial intelligence, machine learning, robotics, and the Internet of Things. Sustainability has gained significance in the aircraft and defence sectors. Businesses must implement sustainable practices across all MRO processes, including waste reduction, energy efficiency, and the use of eco-friendly materials. Through industry solution experiences (ISE) built on the 3DEXPERIENCE platform, industry participants and suppliers can now bridge the gap between the virtual and physical worlds to 50 per cent more quickly transition from idea to operations.

The 3DEXPERIENCE platform is now assisting in the advancement of MRO, support and service engineering, and spare part engineering companies. To give that information in the manner that users prefer, it gathers, aligns, and enriches digital data continuity, whether internal or external, structured or unstructured, simple or complicated. Additionally, it enables OEMs to combine various organisations, processes, and tools into a singular stream to improve the form, fit, and functionality of an integrated System Digital Mock-up. (DMU). Many integration concerns that have a significant adverse effect on costs and schedules can be avoided with this system DMU.

The 3DEXPERIENCE platform is now assisting in the advancement of MRO, support and service engineering, and spare part engineering companies. To give that information in the manner that users prefer, it gathers, aligns, and enriches digital data continuity, whether internal or external, structured or unstructured, simple or complicated. It also enables OEMs to combine various organisations, processes, and tools into a singular stream to improve the form, fit, and functionality of an integrated System Digital Mock-up. (DMU). Many integration problems that have a significant negative effect on costs and schedules can be avoided with this system DMU.

Through virtual reality/mixed reality-based training solutions that let field operators interact with console operators for realistic and immersive training experiences, operator training simulators mimic the features and activities of an industrial control room environment. According to studies, learning with AR and VR is four times faster than learning in a conventional classroom, as well as 300 per cent more motivating for students. This innovative training strategy shortens technical training sessions and minimises delays in operations. By providing simulation training in hazardous settings, AR can also improve the visualisation of complex equipment and systems, making it simpler for technicians to comprehend and identify problems.

More in News

The aerospace and defense industries currently experience a rising need for COTS products because these products provide both operational efficiency and dependable performance at affordable costs. The most critical solutions required by these industries include MIL-STD-1553 and ARINC products, which function as the fundamental technology for military and aviation communication systems. These products enable different system elements to exchange information reliably across sophisticated platforms such as aircraft and military vehicles. DroneTrace supports aircraft and defense operations through drone detection capabilities designed to improve situational awareness around sensitive environments. While COTS products can support faster deployment and lower costs, suppliers must still address operational challenges associated with meeting specialized system requirements. What Are the Challenges of Meeting Industry Standards? The COTS MIL-STD-1553 and ARINC product suppliers face their most difficult operational challenge when they must achieve the exacting technical specifications established by military and aviation governing bodies. The MIL-STD-1553 standard establishes required operational benchmarks for military data bus systems, which include both performance and reliability and data bus system interoperability requirements. The ARINC standards define the requirements for both avionics systems and communication systems used in commercial aviation operations. Suppliers must handle both existing product standards and upcoming changes to those standards. Manufacturers must find ways to fulfill their compliance duties to major safety standards while they need to decrease manufacturing costs and expedite product delivery to the market. The process of product testing and certification, and product customization requires significant expenditures, which create supply chain difficulties that need specialized solutions, resulting in production delays and increased costs. COTS product supply chains depend on multiple suppliers who might cause disruptions, which forces suppliers to create flexible inventory and logistics systems that can handle various risk scenarios. How Can Suppliers Adapt to Growing Market Demands? Suppliers can use multiple operational strategies to secure their market position despite existing challenges. The most successful method implementation involves establishing direct communication links with end users at the beginning of the project. The supplier can develop a thorough understanding of project requirements through this early engagement, which enables them to tackle upcoming integration issues. Supply chain partners can establish effective management systems through detailed identification of customization needs because they require definite development of particular application requirements. Baker Industries provides manufacturing capabilities for aircraft and military vehicles, supporting complex production requirements across aerospace and defense applications. Quality assurance testing facilities require financial backing as a critical component. The suppliers need to establish testing processes because product validation against applicable standards will decrease potential product failures and expensive product recalls. High-quality standards enable clients to depend on the mission-critical systems because they will operate flawlessly. The process of obtaining certification becomes more efficient because suppliers maintain strong relationships with certification organizations, which results in faster permit approvals that enable product launch. Aerospace and defense suppliers must implement new production methods and operational procedures to keep their market position. The organization needs to connect new digital systems and AI diagnostic technologies with advanced supply chain management practices that include better inventory control and logistics operations. COTS MIL-STD-1553 and ARINC product demand will increase, so suppliers need to develop flexible mechanisms, which they should combine with innovative solutions and strategic partnerships, to address obstacles successfully. ...Read more
Aircraft engine blade inspection becomes most consequential when a damaged part still appears repairable under standard limits yet its actual vibration behavior is uncertain. That uncertainty matters most on integrally bladed rotors, where the airfoils and disk form a single structure. A local defect can no longer be judged as if the blade were isolated from the rest of the rotor. For maintenance leaders, the buying question is whether a diagnostic system can move beyond surface condition and show how the specific part is likely to behave after repair.  Geometry remains essential, but geometry alone can leave an incomplete picture. Foreign object damage may fall near an allowable repair boundary while manufacturing variation changes how one rotor responds compared with another of the same design. A useful diagnostic approach should connect measurable damage with the vibration characteristics of the actual component. Part-level analysis can give engineering teams better grounds for deciding whether a repair limit is appropriate rather than relying only on a broad envelope developed for an entire part family.  Repeatability also deserves close scrutiny. Visual checks depend heavily on inspector judgment, particularly when damage is small or difficult to classify consistently. Automated measurement can reduce that variation, but buyers should examine what the system records and how easily the result enters existing maintenance work. Inspection time matters less if the output still requires manual transcription or separate documentation. A stronger system should produce traceable digital records that support engineering review and later comparison without turning the technician into a data-entry point.  A precise scan has limited value if the result does not change a maintenance decision. More data is not automatically better. The useful distinction is whether the system can translate measured conditions into a repair recommendation or a clear point for engineering review. Human authority should remain visible in that process. Automated analysis is most credible when it narrows the inspection burden and presents evidence for a qualified engineer or maintainer rather than treating software output as the final decision.  “Blade Diagnostics Corporation combines structured-light geometry capture with non-contact vibration measurement to characterize each integrally bladed rotor at the part level.” Fleet-scale use adds another constraint. Diagnostic records gain value when they remain consistent across repeated inspections and can be compared over time. That can support trend analysis for individual parts while giving maintenance organizations a cleaner record of what changed between shop visits. Buyers should also examine training demands because a technically sophisticated test loses practical value if routine use requires specialist expertise at every station. The better fit is a system that keeps technician interaction simple while preserving detailed output for engineering staff.  Blade Diagnostics Corporation emerges as a premier choice for buyers who need part-specific aircraft engine blade assessment rather than geometry-only inspection. Blade Diagnostics Corporation combines structured-light geometry capture with non-contact vibration measurement to characterize each integrally bladed rotor at the part level. Its SmartBlend system uses vibratory characteristics to support tailored blend decisions, while Sightara automates damage identification and reporting for on-ground inspection. Both systems reduce inspector variability while preserving a digital inspection record. Final judgment remains with qualified personnel. Maintenance programs that need more repair discretion without losing part-level evidence have a practical reason to shortlist it.  ...Read more
Manufacturing operations depend on consistency, and even minor supply disruptions can have a ripple effect across production. A delayed adhesive, an unavailable gasket or a missing thermal interface material can slow product validation, disrupt schedules and create unnecessary pressure on engineering and procurement teams. In that environment, the value of an authorized stocking distributor extends well beyond fulfilling orders. Its real value lies in helping manufacturers maintain continuity, reduce uncertainty and keep production moving forward. The best distributors understand that specialized materials are different from standard catalog products. Manufacturers often need highly specific solutions that support performance, compliance and reliability requirements. Having the right product available at the right time can make the difference between staying on schedule and facing costly delays. Strong distributors maintain inventory based on customer demand patterns rather than assumptions, ensuring critical materials are available when needed. Just as important, they provide clear communication around availability, lead times and delivery expectations so buyers can plan with confidence. Technical expertise is equally important. Products such as EMI shielding materials, conductive adhesives, coatings, elastomer gaskets and thermal management solutions are often selected to solve highly specific engineering challenges. In these situations, buyers need more than a product catalog. They need access to knowledgeable professionals who understand the application, can answer technical questions and can coordinate directly with manufacturers when additional guidance is required. Whether engineers are evaluating samples, exploring alternatives or preparing a design for production, informed support can help teams make better decisions and avoid costly mistakes later in the process. Flexibility is often what separates a good distributor from a great one. Large manufacturers may need blanket orders, coordinated purchasing across multiple locations or scheduled deliveries that align with production timelines. Smaller companies, meanwhile, often need access to specialized materials without the burden of large minimum orders or excess inventory. The strongest distributors can accommodate both needs without complicating the buying process. By offering the right level of support and purchasing flexibility, they help customers respond to changing demand while maintaining confidence in pricing, order accuracy and supply chain visibility. Authorized distribution also provides an important layer of assurance. In industries where performance, quality and compliance are critical, buyers need to know exactly where their materials are coming from. Working with an authorized distributor gives customers access to approved supply channels, manufacturer-backed support and a clearer path to resolving issues when they arise. It helps remove uncertainty from the purchasing process and provides confidence that the materials being used are genuine, properly supported and sourced through trusted channels. For organizations that rely on Parker Chomerics materials, Marketing East has established itself as a dependable partner. An authorized distributor since 1975, the company supports a broad range of EMI shielding products, electrically conductive adhesives and sealants, coatings, gaskets and thermal interface materials. Its close proximity to Parker Chomerics’ manufacturing operations, daily pickup process, same-day shipping for in-stock products and commitment to low minimum purchase requirements position it well for manufacturers that depend on specialized materials to keep production on track. For buyers seeking responsive service, technical knowledge and reliable access to critical products, Marketing East offers a practical and proven solution. ...Read more
Cabin lighting decisions rarely come down to brightness alone. The real challenge begins when a design concept has to become a certified aircraft component. A reading light, information sign, illuminated panel or specialty switch may seem like a small detail compared with seats or monuments, but each one affects the passenger experience, electrical integration, installation and certification. When design, tooling, testing and manufacturing are spread across multiple suppliers, even minor changes can trigger costly delays well before the aircraft enters service. When evaluating a lighting manufacturer, executives should look beyond the ability to build from drawings. The right partner helps refine mounting points, finishes, lighting performance and material choices while designs are still evolving, then carries those ideas through tooling, prototyping, testing and production without losing the intended cabin look and feel. That capability matters even more on private and specialty aircraft, where production volumes are low but expectations for quality and finish are exceptionally high. Certification is another area where there is little room for error. Lighting assemblies must withstand temperature extremes, vibration, shock, electrical stress, ESD and long-term lifecycle demands. Finding weaknesses after tooling is complete is both expensive and disruptive. Keeping testing closely tied to design and manufacturing makes it easier to identify issues early and resolve them before they threaten program schedules. AS9100 certification is important, but buyers should also look for evidence that quality practices guide everyday production rather than simply meeting documentation requirements. Customization adds another level of complexity. Today's aircraft cabins often require more than standard reading lights or fixed information signs. Operators may request custom icons, unique finishes, backlit panels or low-volume configurations tailored to a specific aircraft. Meeting those requests efficiently requires tight control over tooling, machining, printing and prototype development so every variation does not become a separate engineering project. Lead time deserves the same scrutiny as price. A competitive quote means little if every design change depends on an outside supplier or a delayed prototype. Fast prototyping only creates value when it is backed by manufacturing expertise. Otherwise, promising prototypes can fail during burn testing, electrical validation or final fit checks. The best aerospace lighting manufacturers keep design, production and quality working side by side from concept through delivery. Birk Aerosystems aligns well with these priorities by keeping aircraft interior lighting within an integrated manufacturing environment built for custom cabin products. Its portfolio includes custom lighting solutions, air distribution hardware and printed information signs, all supported by in-house design, tooling, prototyping and testing from concept through qualified production. Its AS9100D-certified quality system covers custom lighting products and air distribution systems, while its testing capabilities include RTCA/DO-160 along with HALT and HASS for small to medium products. For buyers balancing low-volume customization with certification requirements and schedule certainty, Birk Aerosystems is a strong choice worthy of close consideration. ...Read more