During the last decade, aircraft manufacturers have been in a race for mass production, often delaying the adoption of smart digital technologies. Today, amid the COVID pandemic, the sudden plunge in aircraft orders has forced them to take a step back and allowed them time to prepare for necessary structural transformations. Investing into 4.0 technologies to extend existing digital capabilities may look like an extra financial stretch at the moment, yet, this is mission-critical to anticipate for business recovery, for both manufacturers and suppliers.

Performance has always been key but now, more than ever, performance will be a game-changer for every aspect of each aero OEM’s new business model from performance in terms of product quality, production capacity utilization, safety, security, or in terms of operations and maintenance costs.

Engineering managers in the aerospace industry have already started to introduce product lifecycle management (PLM) with advanced simulation tools because it speeds up their workflows and offers effortless decision-making. This is surely a step in the right direction. But obtaining certifications for new aerospace technologies and demonstrating product behavior, while establishing trust in next-generation products prior to market launch and throughout the lifecycle as part of a big fleet, are two sides of the same coin. If they want to efficiently manage this complexity, they need to allow engineers to consider the impact of design decision over manufacturing throughout the whole PLM process and virtually assess the full picture of the final aircraft in real life.

ESI has proven commitment to performance goals since our inception back in 1973, which is why we are evolving product lifecycle management into product performance lifecycle management (PPL). We are convinced that managing the PPL is the gateway for you to get it right®. Together, let's turn the corner in your aircraft’s development.

ESI’s Virtual Prototypes and the Hybrid Twin™ equip engineers with the ability to experiment virtually with real data and real physics, simultaneously. This gives engineers that extra degree of freedom and early confidence they need to design, manufacture, and assemble right the first time - without real tests or prototypes, before cutting a single piece of metal, and with zero downtime during final operations. This is truly an end-to-end digital thread that seamlessly connects product design, manufacturing, and in-service operations and empowers you to bounce back in a truly leaner and greener way.


Can ESI help me secure tolerances and margins?


Our shared mission is to decrease scrap rates and increase productivity by getting products right the first time for various manufacturing processes, including casting, sheet metal forming, composites, and additive manufacturing. Virtual Manufacturing enables a ‘quicker than ever’ investigation and development of new manufacturing and assembly processes, spreading innovation across the entire supply chain. This is a key success factor in beating the ramp-up challenge and keeping pace with the surge of orders. We did this with Rolls-Royce.

Can ESI help me accelerate the deployment of advanced manufacturing capabilities?


The physics of materials makes all this possible, and it is our unique expertise we have developed since our inception in 1973. From heat transfer and fluid flow phase changes to residual stress modeling and more, combine your in-house competencies with ESI's expertise in metallurgy and process performance to find new designs and keep the most strategic parts in your hands.

Can ESI help me speed up my journey towards Factory 4.0?


As factories become increasingly smart, manufacturers ensure that assembly sequences are proficiently performed by debugging design errors and process inefficiencies right from the product development stage.  In addition, an immersive virtual manufacturing world provides you with a full-scale experience to validate and optimize new interactions in production scenarios and to simulate manufacturing operations before any physical prototype is built. We did this with Safran.

Can ESI help me maximize the productivity of my fleet?


Blending the virtual world and the real world is the purpose of ESI's Hybrid Twin™. It collects smart sensor data from real-life fleet operations and is artificially intelligent to predict any maintenance needs based on the current fleet condition. It will advise you on how to adjust single operations (e.g. range) in order to prevent you from any unexpected downtime. And it will make sure all real-life performance-related data will be fed back into the development of your next-generation machines. This is the mission-critical backbone of the digital threat in your enterprise.

Our Solutions to Fulfill on Time Delivery for Twice as Many Planes

Just like in the highly innovative automotive industry, aerospace manufacturers and suppliers have extracted the greatest possible gains from incremental improvements. Now, they must radically embrace virtual prototyping and Hybrid Twin™ to deliver on the new aero mobility expectations in terms of quantity, quality, and technological advancement. Fortified with specific and unique expertise in material science, our cross-functional teams of aircraft and space engineers, manufacturing experts, and data architects enable you to pivot and create incomparable next-generation aircraft technologies.

Read on to find out more about the main value propositions that we offer in the fields of pre-certification, pre-experience, smart manufacturing, and man-machine-interaction (Human-centric).

Integrate and Build Your Next Aircraft 100% as Planned in a Human-Centric Way

In the early design stages and through the eyes of the operators: visualize new concepts before they even exist; deliver better safety & ergonomics for factory operations and increase ROI by getting your products and processes right the first time.

Smart Manufacturing: Confidently Select the Right Production Process Early

Increase productivity and performance in manufacturing processes, ramp up production rates, and move towards innovative methodologies and materials that help you achieve your sustainability targets.

Pre-Experience a New Aircraft’s Performance and Validate Business Models Early

Move towards selling hours of flight instead of engines! Virtually prototype and test new concept designs with confidence and predict the behavior and performance of aircraft technology, in-service, upfront in the development cycle.

Get Pre-certification of New Materials & Structures Right the First Time, Because Agility Matters

Today, it’s possible to launch an ultra-lightweight seat that was developed and tested completely virtually, fulfills all passenger demands, and is certified right the first time – creating ultimate business value in record time.

Trusted By

All over the world, suppliers, manufacturers, and engineering partners use ESI’s solutions to design and optimize future mobility in the air, e.g. Airbus, Alcoa, Avic, Boeing, Bombardier, Dassault Aviation, ESA, General Dynamics, Honeywell, Lockheed Martin, MSI-DFAT, NASA, Northrop Grumman, PCC, Rolls Royce, Safran, Textron Aviation, Thales, United Technologies and many more.