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Productivity challenges in Aerospace Industry

The current product design to the development cycle in the Aerospace Industry is very long, leading to huge losses in time and cost. These losses occur majorly due to the lack of technology adoption by the industry to augment the inaccurate and largely ineffective design review processes that depend on repetitive physical prototyping as a means to validate CAD driven designs. While CAD has helped immensely in improving the initial design conceptualization, it has close to no benefit while used as a review tool simply because of the lack of real scale visualization. Hence the need for building large scale physical replicas (prototypes) for each consecutive review. This repetitive prototyping not only leads to huge losses in time and therefore cost in the design stage but they also failed to address the key challenges that have plagued the industry. The current process completely fails to accurately identify ergonomic related manufacturability and serviceability challenges that once again lead to huge cost and time escalations in the production stages.

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Digital Transformation case studies for Aerospace Industry

Introduction of virtual prototyping

Virtual Prototyping was initially introduced as a means to visualize aircraft designs in a 1:1 scale in a virtual environment. The idea was to completely replace the need for repetitive physical prototyping with a single physical prototype used for the final validation of the design. With Virtual Prototyping, the industry could now accelerate the whole design process. Furthermore, the technology saw advancements in the form of Digital Mockup tools that increased the initial design review accuracy. However, a challenge still, remained the need for data conversion and processing before the model could be brought into the virtual environment.

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Exxar CAD converts any desktop 3D CAD into a collaborative extended reality experience in real-time.

Exxar CAD to VR

With Exxar and its unique ‘no export-no import’ CAD to VR technology, users can instantly transform the native 3D CAD data of the aircraft from the CAD desktop application, into a 1:1 scale, interactive prototype, with just a click of a button. Once the data gets into the virtual environment, the amazing in VR UX allows natural interaction and collaboration in the immersive environment for early validation of various possibilities in the manufacturing stages. Factor in the capability for making interaction focused assessments as well as achieving accurate ergonomic assessments and we can safely say that Exxar is truly revolutionizing the design to development standards in the aerospace industry, eliminating the time and cost escalations in not only the design stages but also the production stages.

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Design Review & Approval

In the current process, designs are created using 3D CAD applications. They are collaborated on and showcased to the stakeholders using print outs, charts, and physical mockups. This complicates the design review process and also causes project milestone delays. With Exxar CAD to VR users can now have access to 3D CAD design data to VR in 1 click without the need for physical prototyping,

  • 1:1 scale model visualization
  • Review with appropriate background environments
  • Collaborative design review
  • Use digital mockup tools
  • Record design errors 
  • Give feedback during the review
  • Instant change assessment in VR

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Before After design review aerospaceAerospace Design Review
design review aerospace

Manufacturability & Serviceability

Before After aerospace manufacturingAerospace Manufacturablity
aerospace manufacturing
Most aircraft designers don’t have access to technologies to assess the manufacturability and serviceability of their designs at the moment. Design and production planning faults like visibility, reachability, tool interactions in the aircraft designs result in expensive rework. This also delays production and leads to huge cost escalations,
  • The virtual layout of the entire aircraft
  • Validate operator interactions in the design stage
  • Validate the visibility of operators
  • Assess blind spots in the model
  • Assess accurate assembly sequencing
  • Negate reachability & accessibility faults
  • Give feedback to the design team
  • Finalize changes in the design stage

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Ergonomics validation of postural stress and strain for operators performing inspection and maintenance both while manufacturing and live operations is currently a highly assumptive process relying heavily on desktop applications leading to inaccurate conclusions. The manufacturing delays are proof that an upgraded system needs to be introduced to counter the challenges

  • Virtual Layout of the whole aircraft
  • Place Virtual human at critical points
  • ‘Possess’ virtual human
  • Perform human tasks, actions
  • Identify postural stress in run time
  • Validate possibility with interpenetration
  • Check tooling viability

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Before After aerospace ergonomicsAerospace Exxar Human
aerospace ergonomics

Product Showcase

Before After aerospace showcaseAerospace showcase
aerospace showcase

Showcase currently relies heavily on physical models with ‘marked’ layout changes or videos or charts, which are either very expensive to set up or lack the immersive edge that keeps the audience engaged. Even in the best of cases, certain change requests increase the cost for introducing further changes

  • Multi-users + 3D CAD in VR meeting
  • Immerse the audience in 1:1 scale
  • Set context with background environments
  • Collaborate with all stakeholders if required
  • Note customer feedback during the showcase
  • Real-time change request in CAD
  • Live showcase of a modified design

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The chance for accidents during operations has always been a concern in the aerospace industry. Training currently is in non-engaging classrooms or computer-based training. On the job training, on the other hand, is very expensive, further increasing risks at the job site

  • Final model data from CAD to VR
  • Familiarise operator in 1:1 scale with a model
  • Improve layout understanding
  • Perform operator tasks in VR

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Before After aerospace maintenanceAerospace Training
aerospace maintenance

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FAQ (Frequent Asked Questions)

Exxar supports all the major 3D CAD applications. CATIA, Solidworks, NX, Navisworks, etc.

Exxar streams CAD models in X Reality in Real-Time.

  • Exxar  projects the model in VR with a single click of a button in less than a minute. 
  • Regardless of model size Exxar guarantees CAD to VR in less than a minute.

Exxar Supports various VR hardwares from OEM’s like HTC, Oculus, ART, Manus, Barco to name a few

Yes Exxar allows collision visualization when parts collide/interfere with each other. It also showcases Tool to part collisions while analysing operator interactions. Furthermore, with Human mode we can also check hand to part as body to part collisions.

  • Exxar cloud has the feature to save the changes and create sessions for future reference. You can access your session where it was saved.
  • Through annotations reviewers can share his/her feedback with designers.

Yes, if the CAD model has Metadata that can be viewed through the ‘Information’ button in the Exxar panel.

Exxar has a feature of ‘X-ray’ which allows you to see through the outer-l of ayer of the models, making the selected layer transparent in Exxar view.

  • Through Exxar Human Module users can load and possess a mannequin in XR environment by wearing full body tracking suits. 
  • With this, one can analyse and validate all human centric activities more accurately.
  • Since the mannequin in VR is calibrated to our real body, all interaction activities with the model will be highly accurate. This means that all posture related issues (effecting reachability and accessibility) can be accurately assessed.
  • Through Exxar Human Module users can place multiple mannequins in XR to evaluate the reachability and accessibility.
Exxar meets the requirements of Aerospace designing as it has following basic features: 
  • Immersive experience– It is the fundamental for development of Exxar.  To provide High image quality for better visualisation.
  • Large Data Handling: As Aerospace has to consider multiple aspects in designing it require High-end computation for complete visualisation. Exxar has user-friendly operations for large data handling.
  • Live connection with CAD application:  Exxar has a really quick streaming from CAD to XR that is user friendly. Real-time visualisation is the USP of Exxar CAD

Exxar stream is a real time visualisation software that displays the model changes saved in the CAD application. Edited CAD models can be seen in X Reality within seconds.