Siemens Showcases Digital Twins at Paris Air Show 2025 to Slash Aircraft Production Costs
Siemens Showcases Digital Twins at Paris Air Show 2025 to Slash Aircraft Production Costs
At the Paris Air Show 2025, Siemens is spotlighting how digital twins are transforming aerospace production, cutting manufacturing costs while accelerating timelines.
Digital twins—real-time, virtual replicas of physical systems—are now essential to aerospace OEMs. These systems enhance every phase of product development, from design and engineering to scaled manufacturing and long-term maintenance.
According to Todd Tuthill, VP for aerospace, defense, and marine industry at Siemens Digital Industries Software, clients using Siemens’ digital twin technology have halved their manufacturing costs. He told AIN that engineering rework was reduced from 20% to just 1% among top aerospace and defense primes.
California startup JetZero, working with Siemens and its Xcelerator platform, is using the tech to certify a 250-passenger blended-wing-body airliner within five years—significantly faster than the time it took Boeing’s 787 or Airbus’s A350. “They can’t afford mistakes,” said Tuthill. “The digital twin allows them to fly the aircraft before it’s built and build it before the factory exists.”
JetZero’s investors include Delta, United, and Alaska Airlines. With digital twins, engineering errors can be resolved virtually before physical production begins. “I want to make the mistakes early. I want to do them in a digital world so I can correct them before I’m ever in a physical world,” he added.
Digital twins are also optimizing production line planning. Factory construction can cost hundreds of millions, and errors are costly if discovered after operations begin. “I can’t wait to build a factory to find out I [designed] it wrong,” Tuthill explained. Simulating workflows ahead of construction improves both efficiency and FAA production certification timelines.
“They’re betting their company on our technology—that they’re going to design it right the first time [and] that their manufacturing will be production-certified on time,” said Tuthill.
Immersive Engineering on Display
This week at the Paris Air Show, Siemens unveiled its newest advancement: the NX Immersive Designer software, shown running on Sony’s SRH-S1 XR headset. The demo lets users experience immersive 3D engineering environments that Siemens says pave the way for the “industrial metaverse.”
Engineers can visualize and interact with digital twin models in real-world industrial settings while preserving natural vision. The system integrates augmented reality, generative AI, and voice controls for an intuitive, hands-free experience. The headset features 1.3-type OLED 4K microdisplays and includes precision controllers for real-time interaction.
Commercial launch is slated for December. Siemens says the tech allows engineers to engage with realistic 3D renderings, similar to Star Trek’s holodeck. “The holodeck is going to be around pretty soon, and we are one of the leading companies in technology delivering that,” said Tuthill.
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