What is `Virtual Twin Technology’, Dassault Systemes game-changer for the Indian aerospace and defence sector – Business News

Dassault Systemes is playing a key role in the transformation of India’s Aerospace and Defence sector through the use of Virtual Twin technology, leveraging the capabilities of the 3DEXPERIENCE platform. This advanced technology enables companies to design, test, and optimize complex systems in a virtual environment, well before any physical production begins.

Talking to FinancialExpress.com on the sidelines of Aero India 2025 in Bengaluru, Deepak NG, Managing Director, Dassault Systemes India, says, “Virtual Twin technology allows Indian aerospace and defence companies to create highly detailed digital replicas of their assets like aircraft and satellites.”

“These replicas help analyze aerodynamics, structural integrity, and performance to make optimal design decisions before moving to physical prototypes. Additionally, it enhances manufacturing efficiency by simulating production processes, identifying bottlenecks, and minimizing material waste,” he said.

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According to him the benefits extend beyond design and manufacturing. Virtual Twin technology integrates real-time data for predictive maintenance, improving the reliability and longevity of defence assets. “The 3DEXPERIENCE platform facilitates seamless collaboration across design, engineering, and maintenance teams, enabling efficient decision-making and optimized workflows.”

Virtual Twin Technology

Moreover, Virtual Twin technology has a key role in fostering sustainability within the industry. It allows for the simulation of fuel efficiency, emissions, and material usage, enabling more eco-friendly innovations. “By accelerating time to market, reducing costs, and fostering innovation, Dassault Systemes supports India’s Atmanirbhar Bharat initiative, empowering domestic aerospace and defence companies to develop advanced systems independently,” adds Deepak NG.

Sustainable Practices

In collaboration with key stakeholders, including the Indian government, Dassault Systemes is promoting sustainability within the aerospace and defence sectors. According to him, “Through policy development, funding support for green technologies, and capacity-building initiatives, the company aligns its efforts with national sustainability goals, including the UN Sustainable Development Goals (SDGs).”

“Government involvement has been instrumental in strengthening SMEs and the Aerospace & Defence ecosystem in India. By providing schemes and support to adopt sustainable technologies, these initiatives help solidify collaborations with OEMs for research and production,” he explains.

Virtual Twin Technology on Environmental Footprints

During the design phase, virtual validation helps manufacturers test and refine green aviation alternatives such as hydrogen fuel and electric battery-powered aircraft, reducing material waste and energy consumption.

“In the manufacturing phase, virtual twins facilitate predictive maintenance and resource optimization, minimizing waste by identifying potential issues before they escalate. Real-time insights into production processes help optimize resource utilization and improve efficiency, ultimately leading to reduced material wastage,” Deepak NG highlights.

Virtual twins also contribute to lower energy consumption in the operational phase by streamlining workflows and optimizing resource allocation, helping ensure sustainable use of raw materials and infrastructure. Together, these applications lead to significant reductions in carbon emissions, energy use, and material waste, making Virtual Twin technology a crucial enabler of sustainable innovation in aerospace.

Integrating Sustainability-Focused Technologies

Despite the promise of sustainability-focused technologies, there are barriers to their adoption in the aerospace and defence sector. High upfront costs, regulatory uncertainty, and supply chain complexities are just a few of the challenges companies face. “Many sustainable solutions, such as electric propulsion or advanced composite materials, require substantial capital investment, which can be a challenge for budget-conscious companies,” Deepak NG acknowledges.

According to him the platform enables real-time testing and design refinement, helping companies reduce costs and material waste while fostering collaboration among design, manufacturing, and supply chain teams to integrate sustainable practices.

“The ability to conduct real-time simulations ensures early detection of design flaws, reducing reliance on costly physical prototypes and speeding up time to market,” he says.

AI also plays a crucial role in Predictive Maintenance, analyzing operational data to predict when maintenance is needed, reducing downtime, and enhancing safety. By automating these processes, AI accelerates the pace of innovation, establishing its transformative role in the defence sector.

The company invests in training programs, collaborates with educational institutions, and partners with state governments to establish Centers of Excellence (COEs) for skill development. “We equip engineers with expertise in advanced software platforms like CATIA, DELMIA, and ENOVIA, ensuring they are industry-ready,” explains Deepak NG.

The company also partners with leading universities and research institutes to integrate its technology into academic curricula, fostering innovation through hands-on experiences. And has invested in a state-of-the-art training facility in Assam and established COEs in Karnataka, Tamil Nadu, and Andhra Pradesh, dedicated to developing aerospace and defence skills.

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