Virtual Integrated Aircraft: A Methodology for Early Aircraft Systems Integration with Simcenter Systems Simulation
The aerospace industry is facing unprecedented levels of complexity. Electrification, software-intensive architectures, thermal management challenges, and increasingly demanding verification and certification activities are transforming the way aircraft are designed and developed. At the same time, integration activities continue to consume a significant portion of program schedules and resources.
To address these challenges, Siemens has developed the Virtual Integrated Aircraft (VIA) methodology. More than a simulation model, VIA is a structured systems-engineering methodology that enables aircraft systems to be designed, integrated, verified, and analyzed within a unified digital environment from the earliest design stages.
This article explains the VIA methodology and the role played by Simcenter systems simulation tools in supporting it.
Why the Aerospace Industry Needs Virtual Integrated Aircraft
Aircraft development has evolved from a largely document-based engineering process toward a model-based and simulation-driven approach.
Historically, aircraft programs were characterized by:
- Sequential development processes
- Discipline-specific engineering silos
- Heavy dependence on physical prototypes
- Late discovery of integration issues
- Limited use of simulation during early design phases
Modern aircraft programs require a fundamentally different approach. Emerging technologies such as:
- Distributed electric propulsion
- Advanced thermal management
- Increased software content
- Highly integrated electrical and mechanical architectures
have dramatically increased cross-domain interactions.
According to research, aircraft programs often spend 30–70% of schedule and resource time addressing integration issues, while only a limited portion of the industry has begun its transition toward Model-Based Systems Engineering (MBSE).
The challenge is not simply to design individual systems. It is to understand how propulsion, fuel, environmental control systems, thermal management, electrical networks, and control systems behave together during an aircraft mission.
The Virtual Integrated Aircraft methodology addresses this need by creating an early, scalable digital twin of the aircraft, allowing engineers to understand system interactions long before physical integration occurs.
What Is the Virtual Integrated Aircraft Methodology?
The Virtual Integrated Aircraft methodology is a systems-engineering framework that supports simulation-driven development and virtual system integration throughout the aircraft development cycle.
Its primary objective is:
To achieve aircraft systems virtual integration in the very early phases of the design cycle.
VIA establishes a virtual counterpart to the traditional engineering V-cycle. This virtual V-cycle provides system-level insights before expensive physical testing and integration activities take place.
- Model-Based Systems Engineering (MBSE)
- Multidomain system modeling and simulation
- Verification and validation workflows
- Digital-thread continuity across engineering teams
A key characteristic of Virtual Integrated Aircraft is its adaptability. The methodology can be aligned with different aircraft manufacturers’ organizational structures and system breakdown strategies.
Instead of creating large, monolithic simulation models, VIA promotes the creation of models that are:
- Modular
- Robust
- Manageable
- Collaborative
The objective is to move away from flat and difficult-to-maintain aircraft models and toward structured architectures that can be shared, verified, reused, and integrated across teams.
This structured approach enables organizations to build digital aircraft representations that remain understandable and scalable throughout the program lifecycle.
The Five-Step VIA Modeling Process
At the heart of Virtual Integrated Aircraft is a five-step methodology that defines how simulation models are created, validated, integrated, and used.
Step 1: Analysis Request
The process begins with a clear definition of the modeling intent.
This phase focuses on:
- Defining simulation objectives
- Identifying stakeholders
- Determining required model fidelity
- Establishing key performance indicators (KPIs)
- Anticipating future integration interfaces
Typical simulation objectives may include:
- System sizing
- Control validation
- Thermal load analysis
- Energy consumption evaluation
A Model Requirements Document captures the modeling rules, expected outputs, and required accuracy.
The methodology fo Virtual Integrated Aircraft also emphasizes early system decomposition, identifying relevant subsystems such as:
- Propulsion
- Environmental Control Systems (ECS)
- Fuel systems
- Electrical systems
By clarifying the purpose of the model from the beginning, downstream modeling activities become more efficient and consistent.
Step 2: Model Creation
Simulation engineers then create component and subsystem models.
Key principles include:
- Defining parameters, objectives, and constraints
- Performing unit-level validation
- Maintaining modular architecture
- Creating reusable model libraries
- Documenting assumptions and limitations
The architecture also introduces the concept of interface contracts, which define:
- Mechanical interfaces
- Electrical interfaces
- Thermal interfaces
- Control interfaces
This allows components to be developed independently while remaining compatible with future integration activities.
Another principle is scalability. A component may exist at different levels of fidelity depending on the intended use case, while maintaining the same integration interface.
Step 3: Quality Check and Sharing
Before integration, models undergo quality and robustness assessment.
Activities include:
- Accuracy evaluation
- Sensitivity analysis
- Independent peer reviews
- Validation testing
- Repository publication
The objective is to establish confidence in the models before they become part of larger integrated architectures.
Step 4: Model Integration
Validated subsystem models are then integrated into larger aircraft-level architectures.
Because interfaces were defined upfront, integration efforts are significantly reduced.
The Virtual Integrated Aircraft methodology supports the integration of heterogeneous models through:
- FMI-based workflows
- Co-simulation
- Reduced-order models
- Data mapping from 3D CAE simulations
The resulting integrated architecture becomes the foundation of the aircraft digital twin.
Step 5: Scenario Simulation
The final phase uses the integrated model to evaluate mission-level behavior.
Engineers can perform:
- Mission simulations
- Design-of-experiments studies
- Trade-off analyses
- Variant comparisons
- Requirement verification
This enables design decisions to be evaluated virtually before physical testing begins
Simcenter Tools Supporting the VIA Methodology
The Virtual Integrated Aircraft methodology is supported by a set of Simcenter systems simulation solutions that address modeling, testing, collaboration, and lifecycle management requirements.
Simcenter Amesim
Simcenter Amesim is used to develop the modular system architectures that form the basis of VIA.
It supports:
- Multidomain physical modeling
- System decomposition
- Library creation
- Reusable component development
- Aircraft-level integration
The methodology specifically highlights the creation of structured model architectures within Simcenter Amesim.
Simcenter Test Manager
Model robustness depends on continuous verification.
Simcenter Test Manager supports:
- Automated testing
- Validation criteria definition
- Test suite creation
- Regression testing
- Model update verification
- Automated reporting
The platform enables validation across multiple environments, solver configurations, and software versions.
Simcenter Client for Git
As Virtual Integrated Aircraft system models grow in complexity, version control becomes essential.
Simcenter Client for Git provides:
- Branching workflows
- Version management
- Model traceability
- Library management
- Team collaboration
The presentation emphasizes the importance of managing not only models but also associated data such as parameters, documentation, validation datasets, drawings, and custom code.
Teamcenter Integration
The Virtual Integrated Aircraft methodology also relies on Teamcenter for enterprise-level model management.
This enables:
- Model publication
- Metadata management
- Digital-thread continuity
- Traceability
- Enterprise-wide sharing
Together, these tools provide the infrastructure required to make VIA practical across large engineering organizations.
From Digital Integration to Faster Decision-Making
The value of Virtual Integrated Aircraft extends beyond model creation.
By combining MBSE, simulation, verification, model management, and digital-thread continuity, the methodology creates an environment where engineering decisions can be made earlier and with greater confidence.
The presentation illustrates this capability through mission-level simulation examples comparing different aircraft propulsion architectures, including conventional configurations and hydrogen fuel cell-based alternatives.
Because requirements, models, validation activities, and simulation results remain connected, engineers can:
- Evaluate technology choices earlier
- Reassess design decisions quickly
- Analyze complete mission performance
- Verify requirements virtually
- Reduce dependence on physical prototypes
Ultimately, Virtual Integrated Aircraft supports a shift from late-stage integration and problem discovery toward early virtual integration and informed decision-making.
Conclusion
The Virtual Integrated Aircraft methodology is a structured framework for aircraft systems development that combines MBSE principles, multidomain simulation, verification workflows, and digital-thread continuity.
Rather than treating simulation as an isolated engineering activity, Virtual Integrated Aircraft positions modeling and simulation at the center of aircraft development. Through a five-step process—analysis request, model creation, quality checking, model integration, and scenario simulation—it enables early virtual integration of aircraft systems and supports the creation of scalable aircraft digital twins.
Supported by tools including Simcenter Amesim, Simcenter Test Manager, Simcenter Client for Git, and Teamcenter, the methodology provides a practical approach to managing complexity, improving collaboration, and accelerating decision-making across modern aerospace programs.
Want to know more about Virtual Integrated Aircraft? Read about NEWBORN research project about fuel cell powertrain aircraft digital twin. https://newborn-project.eu/mea24/
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