The aerospace industry consists of manufacturing enterprises engaged in vehicular flight within and beyond Earth’s atmosphere.
Main trends:
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Reducing flight costs and emissions through electric and hybrid engines
Aircraft engines must generate more power while consuming less fuel, producing less noise, and emitting fewer pollutants. To achieve this, the industry is improving the efficiency of combustion engines while also exploring electric and hybrid propulsion systems. The aeroacoustics of these engines will also be a critical design focus, especially as drones and urban air mobility (UAM) vehicles begin operating over densely populated areas.
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Autonomous flight systems
Companies are developing business models for UAM aircraft systems to connect regional airports. The economics of UAM are viable only with a single pilot or a fully autonomous system. Single-pilot aircraft require a high degree of automation and cockpit redesign. To develop fully autonomous aircraft, engineers must conduct closed-loop simulations between sensors, control software, and intelligent algorithms. Virtual reality and multiphysics simulations are essential for thoroughly testing these systems within a reasonable timeframe.
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Simulated data for predictive maintenance
Engineers use simulated data to better understand and predict system performance. Predictive maintenance is already generating significant cost savings, but current predictions are less effective for new technologies because they rely on historical data. The industry cannot afford to wait for a decade’s worth of operational data from next-generation flight systems. Therefore, simulated failure data is used to bridge the gap.
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Consolidating and lightweighting aerospace parts
Additive manufacturing (3D printing) is a growing trend in aerospace, particularly for metal components. When combined with topology optimization, it not only reduces weight but also consolidates multiple parts into single components, cutting assembly costs and time. Fewer, lighter parts simplify maintenance and improve fuel efficiency. Additionally, additive manufacturing allows aerospace manufacturers to produce parts on demand, enhancing supply chain efficiency.
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Multiphysics simulations
All these advancements share a common challenge: increasing complexity, which introduces risks that can be costly in terms of both time and money. The aerospace industry has traditionally relied on a compartmentalized approach, where engineering teams focus on individual physics domains before passing results to other teams. However, modern aircraft have become too complex for this siloed method. Solving these challenges requires a shift toward multiphysics simulations, which integrate multiple engineering disciplines simultaneously. Although this shift represents a major mindset change, companies like Virgin Galactic and SpaceX have already demonstrated its necessity and effectiveness in the space sector.
