Traditional design frameworks are facing significant disruptions in the rapidly evolving landscape of global security, driven by technological advancements. These shifts have spurred the development of novel tools designed to modernise and support integrated power structures. Among the most critical drivers of current competition in the international system is the race to update military systems and equipment that align with both present and future mission requirements, a key factor in the quest for global dominance.
In this context, traditional engineering and acquisition methods are proving inadequate in providing effective solutions to meet the changing and increasing security threats. This has paved the way for digital engineering—a new approach that leverages advances in computing, data management, and analytical capabilities. Digital engineering enables the integration of digital models with simulations, alternatives, and systems, providing a comprehensive framework for accurately predicting the performance of new weapon systems.
The Evolution of Digital Engineering
Historically, military contractors relied on computers to design weapon systems, beginning with the creation of preliminary physical prototypes. These prototypes were tested in real-world scenarios, with adjustments made based on observed shortcomings, ultimately leading to the final product. This process, while thorough, was lengthy and costly.
With the advent of the digital revolution, defence industries are now adopting digital engineering to create advanced modelling tools capable of simulating the entire life cycle of a weapon—from initial design through to production, testing, and maintenance. This approach significantly shortens the timeline for designing, building, and testing military equipment in a virtual setting with a high degree of accuracy and at a reduced cost before moving into physical manufacturing.
A Solution to Complex Defence Acquisition Needs
Unlike traditional engineering, where collaborative project management relied on software like Google Docs or Microsoft Teams, complex and large-scale acquisition projects today require all stakeholders to access unified documents, models, and data associated with the programme. Advances in technology, cloud computing, and big data have revolutionised traditional engineering practices, culminating in what is now known as “digital engineering.” The US Department of Defence defines this as an integrated digital approach that uses trusted sources of system data and models across disciplines to support system life cycle activities.
While the use of models for defence acquisition is not new—US military leaders began employing systems engineering decades ago to manage the increasing complexity of Department of Defence programmes—the field initially depended on physical models and paper documentation. Since the 1980s and 1990s, however, the adoption of computer-aided design (CAD) and computer-aided manufacturing (CAM) has enabled faster and more precise task completion by major defence contractors.
The Emergence of Model-Based Systems Engineering (MBSE)
In the early 2000s, “model-based systems engineering” (MBSE) emerged, replacing traditional paper-based design documentation like 2D schematics and programme requirement documents with digital models such as CAD and CAM. MBSE allowed engineers and stakeholders to use simulation and digital testing to create and assess new designs. Despite its advancements, MBSE applications relied on isolated models that couldn’t integrate decisions and functions across various stakeholders.
An Integrated Approach
Digital engineering emerged to address these limitations by combining MBSE with cloud computing tools, big data analytics, and high-speed networks. This enables the creation of large-scale virtual prototypes for new weapon systems before any physical prototype is built and facilitates the development of digital twins of existing equipment. Digital engineering accelerates all phases of the programme life cycle, achieving seamless integration across activities and facilitating precise technical and design choices. It also improves production quality and speed, while ensuring comprehensive oversight of all programme components. The growing importance of digital engineering is further bolstered by advancements in data processing, big data analytics, cloud computing, and storage capabilities. Today, these digital models can be securely stored and shared through networks that allow stakeholders access at any time. Engineers can instantly update designs, which are then immediately accessible to all stakeholders, fostering unprecedented levels of collaboration and coordination.
The Role of Digital Engineering in Accelerating Defence Acquisition and Development Cycles
In the face of the accelerating pace of threats on modern battlefields, digital engineering is enhancing military defence capabilities and integrating emerging technologies into legacy systems. This integration not only provides a competitive edge but also fosters greater preparedness.
Recent American reports have highlighted the role of digital engineering in advancing defence innovation across three main areas.
The first area centres on accelerating prototype design processes. Digital engineering is revolutionising design review methods, particularly in the development and modelling of unmanned aerial systems, while also enhancing next-generation combat vehicles. Through precise digital simulations, these systems undergo optimised design processes, significantly reducing the time needed to transition from initial design concepts to fully functional prototypes. Consequently, digital engineering may shorten the time required to bring innovations to market by over 50%.
The second area focuses on integrating emerging technologies. Modelling and simulation, alongside artificial intelligence, form part of a powerful toolkit capable of combining advanced technologies with legacy systems. This integration streamlines operations, boosts the effectiveness and reliability of military assets, and offers proactive protection against potential issues. It also enhances the military’s capacity for rapid operational response. Extending beyond combat functions, this integration supports maintenance and sustainability, as digital engineering allows for accurate maintenance forecasting, reducing costly downtime and maximising operational readiness while extending the service life of military equipment.
The third area involves enhancing touchpoints for combatants. Digital engineering enables faster, more robust training, allowing soldiers to receive the latest, most realistic training on advanced technologies through sophisticated tools that closely simulate real-life scenarios.
This approach not only improves preparedness but also facilitates the customisation of equipment to meet the specific needs of different units. Thus, adaptability becomes a crucial factor in enhancing overall effectiveness and the readiness of military units.
Moreover, a report from the Mitchell Institute for Aerospace Studies, part of the Air and Space Forces Association, highlighted the critical role digital engineering plays in expediting the defence acquisition and development cycle amid strategic competition. The US Air Force focuses on digital engineering as it faces strategic challenges from Russia and China. The report notes that current capabilities, such as the Air Force’s Rapid Capabilities Office and Space Rapid Capabilities Office, are not designed to deliver broad defensive capabilities, limiting their impact. Digital engineering, however, offers a more comprehensive solution by enhancing requirements analysis, production quality, and efforts in modernisation and sustainability.
Digital engineering also leverages modern IT infrastructure, including high-speed, secure networks and cloud-based storage solutions. This setup enables real-time data sharing among engineers and stakeholders from a centralised and synchronised source, streamlining collaboration and enhancing efficiency across defence programmes.
Growing Interest in Digital Engineering Amid International Competition
Digital engineering has become a key factor in current international competition due to its ability to develop and deploy new capabilities faster and at a lower cost. It encompasses advancements in computing, data analysis, and cloud storage, along with secure information sharing. These innovations promise to revolutionise design, modelling, simulation, and systems engineering practices, enabling the integration of the entire lifecycle of defence systems—from initial requirements through testing, manufacturing, operation, and sustainment.
Digital engineering is described as the “natural and transformative evolution of engineering practices,” leveraging major advancements in computational power, data analytics, and secure information transfer tools. It combines traditional digital modelling and simulation tools with the latest developments in networking, processing, and systems engineering to build a “digital thread”—a structure similar to collaborative platforms in the private sector. This integration can significantly enhance efficiency and quality across the entire system lifecycle.
China has emerged as a leading power in digital engineering, enabling it to accelerate its military capabilities at a faster pace than the United States. For instance, China took approximately 30 years to develop a counterpart to the American F-15 fighter jet but only 10 years to replicate the F-22. While the US currently takes around 16 years to develop and deliver new weapons systems, China requires just 7 years to achieve similar advancements, giving it a crucial operational edge. Projections suggest that China could complete its military modernisation by 2027, positioning itself as a global military power well before 2049.
US Air Force Secretary Frank Kendall echoed these concerns in May 2024, warning that China has spent the past two decades building a military capable of deterring and potentially defeating the United States in the Western Pacific. He emphasised that the US must rebuild its capabilities to keep pace with China, noting that digital engineering will be vital to achieving American goals in this regard. The current approach to acquisition and capability development within the US Department of Defense cannot compete with, or even match, China’s speed and efficiency.
As a solution, some experts propose digital engineering as an effective alternative to help accelerate US defence acquisitions and keep up with China, without the need for major policy reforms. Digital engineering can address many of the delays associated with the Department of Defense’s acquisition processes, aiding in requirements development, speeding up design and selection, and simplifying program management.
Can the United States Rely on Digital Engineering to Regain Military Dominance?
The United States faces growing challenges to its military capabilities, partly due to a significant decline in resources across various sectors. For decades, technological superiority has sustained the US’s military dominance, but the recent focus on counterinsurgency operations and budget pressures have eroded this edge—particularly within the Air Force, which now has the smallest fleet in its history.
Western reports indicate that the traditional acquisition, development, and sustainment approaches of the US Department of Defense (DoD) have become too costly and ineffective for meeting combat needs. The slow pace of modernisation has hindered the US’s ability to keep up with international competitors, particularly China. Traditional efforts to reform the US acquisition policy have failed to achieve the necessary speed and flexibility for developing and deploying new capabilities, resulting in a loss of innovation and agility compared to its rivals.
Historically, the US military has relied on traditional systems engineering, which involved manual processes and extensive documentation for various stakeholders. This approach is time-consuming and costly, limiting the rate at which advanced weapon systems can be introduced.
Digital engineering has emerged as a promising approach for the US military to reassert its dominance amid the current geostrategic competition. This technology provides a suite of effective tools that can enhance the speed and quality of the US’s military capabilities by leveraging advanced computing developments and model-based program management. Consequently, digital engineering could accelerate engineering, acquisition, and production processes within the DoD. These technologies address multiple acquisition challenges, including high costs, lengthy timelines, and maintenance burdens.
In an effort to strengthen its aerial capabilities, the DoD has been advised to make digital engineering mandatory for all future programs. This includes offering incentives for key Air Force contractors to increase the adoption of digital engineering within their supply chains.
In June 2018, the DoD released its first digital engineering strategy, outlining the Air Force’s vision for using digital technology to improve acquisitions. The strategy’s primary goals are to enhance the quality and performance of Air Force systems. Reports have suggested that these goals could be achieved through improved design, timelines, and cost-efficiency in acquiring new weapon systems.
In May 2024, the DoD announced a new digital engineering policy aimed at updating its traditional engineering and acquisition processes through the use of advanced technologies, modelling, and simulation to tackle engineering challenges. This policy emphasises the need for accelerated technological change amid increasing threats and budget constraints. Through this policy, the US military can transition from legacy manual processes to digital environments, allowing engineers, logisticians, program managers, and contractors to test designs, conduct simulations, and manage maintenance, ultimately saving time and costs.
In this context, the RAND Corporation published a report evaluating the US Air Force’s use of digital engineering. The report found that implementing digital engineering requires investment in IT, data management, and training and retaining a qualified workforce. Nevertheless, the assessment showed that the greatest benefits of digital engineering are realised during the operation and support phases, where it has improved performance, cost efficiency, and timelines. Digital engineering has also enhanced systems engineering and innovation during production and development, reducing the need for physical testing.
Current Challenges
Despite the transformative potential of digital engineering, several challenges may hinder its widespread adoption. One significant issue involves component suppliers for new systems, who might lack access to the necessary software or find their systems incompatible with those used by primary contractors. Additionally, some estimates suggest that digital engineering technology could be prohibitively expensive for certain companies, potentially requiring military institutions in some countries to participate in financing efforts.
Another challenge pertains to the availability of a trained workforce capable of using new digital engineering tools, coupled with cultural and bureaucratic resistance from certain military elites. Cybersecurity threats also pose a concern for nations increasingly relying on this technology to develop new weapon systems. Furthermore, some analysts note that digital engineering outputs are still maturing and need time to be verified through physical testing. They argue that, in some cases, simulation cannot fully replace real-world testing.
In conclusion, experience with digital engineering in defence acquisition programmes underscores the need for goal-oriented action plans tailored to each programme, along with effective interoperability management across stakeholders. Additionally, adopting strategies to recruit and retain skilled personnel is crucial, as is managing cultural change. Ultimately, digital engineering is expected to significantly impact the sustainment phase of new weapon systems.
By: Adnan Mousa (Assistant Lecturer, Faculty of Economics and Political Science – Cairo University)
