Northrop Grumman’s Digital Engineering Drives Down Costs

In a recent demonstration, Northrop Grumman Corporation (NYSE: NOC) incorporated its digital ecosystem and advanced production capabilities to build wings for the Model 437 technology demonstrator flown by company subsidiary Scaled Composites. Development began in the fully connected digital ecosystem with Northrop Grumman, the customer and supplier users collaborating to develop, analyse, build and test the wings ahead of the Model 437’s first flight, which occurred on August 29.

The Digital Pathfinder project demonstrated how the company’s fully digital engineering ecosystem reduces engineering rework, accelerates schedule and reduces costs, offering advantages to customers on future aircraft programs. By utilising real-world experiences gained on programs, including the B-21 Raider, the company continues to evolve its collaborative digital ecosystem, which connects the company, customers and supplier partners through the design, development and test phases on a variety of current and future programs.

"We continue to refine these digital tools and capabilities to continuously improve them for future efforts," said Colin Miller, vice president of engineering, Northrop Grumman Aeronautics Systems. "This project demonstrates how high-fidelity models within our digital ecosystem serve as a single source of truth to streamline testing and certification on future aircraft, significantly saving cost and time for our customer."

The digital ecosystem cut engineering rework and redesign to less than one percent, compared to the 15-20% experienced using traditional methods. The demonstration also leveraged high-fidelity models combined with rigorous and approved model validation schemes to reduce requirements for ground and flight tests. Looking forward, these models show the potential to significantly reduce the workload required to determine airworthiness, offering further cost and schedule savings opportunities. 

Through Digital Pathfinder, Northrop Grumman’s high-integrity digital thread connected engineers, customers and stakeholders in a virtual environment, allowing them to proactively foresee and solve the types of problems that typically plague acquisition programs up front and early — greatly improving program performance.

The demonstration also utilised advanced manufacturing techniques, including the production of a titanium structural bracket using plasma arc energy deposition. The application of this innovative additive manufacturing technique to form a titanium part is believed to be a first in the defence industry. At the same time, the Digital Pathfinder project applied advanced techniques to reduce the requirements for hard tooling while improving first-time quality and reducing manufacturing rework.