AviTrader sponsorship ad

Digital Twins in the Hangar – Predicting Failures Before They Happen

predictive maintenance aircraft avitrader
(c) Shutterstock

Helping MROs be more proactive than reactive by reducing unplanned AOG incidents

Aircraft maintenance is a constant battle between safety, efficiency, and cost control. Traditionally, maintenance has involved scheduled checks, routine inspections, and reactive repairs. Though these practices have ensured that aviation remains the safest mode of transport, there exists a fair degree if inefficiency. For example, parts are sometimes replaced earlier than necessary, while in other cases problems may only be discovered once they have already escalated. However, more recently, a new technology has begun to transform how maintenance teams approach many MRO challenges: the digital twin. This innovation aims not only to reduce maintenance costs and increase efficiency, but its trump card is the ability to predict failures before they happen.

What is a digital twin?

A digital twin is not just a static 3-D model or a simple database. It is an intelligent, dynamic virtual replica that continuously mirrors the behaviour of an aircraft or one of its many components in real time. A digital twin may begin with a structural representation of a physical system, but its real power comes from the constant stream of live data it ingests from sensors across strategically located across aircraft. This information—ranging from vibration and pressure readings to temperature changes and fuel efficiency metrics—is processed through a combination of advanced analytics and artificial intelligence. And the result? A living, evolving replica that can simulate multiple scenarios, anticipate failures, and even test different maintenance strategies before any action is taken on the actual aircraft in question.

In the hangar, digital twins are already demonstrating how effective predictive maintenance can be. Consider, for example, a landing gear strut that is fitted with multiple sensors. Instead of being inspected only at scheduled intervals, its digital twin continuously monitors operational stress patterns. When it detects unusual data trends, the twin can predict that a hydraulic seal might soon fail, but of greater importance, it anticipates this long before the issue might be picked up during a traditional check. In this way, engineers gain the upper hand by being able intervene early, preventing costly downtime as well as avoiding potentially dangerous situations. Beyond predictive maintenance, digital twins also make it possible to run virtual tests and simulations. Engineers can examine how components will react to extreme weather, high-cycle operations, or emergency conditions, all without risking damaging real hardware. Through the use of digital twins, maintenance schedules can now be dynamically adjusted according to actual aircraft usage rather than sticking to rigid timetables, and each component’s health and history can be more effectively tracked across its entire lifecycle.

Already seen benefits of digital twins

The benefits for airlines and MROs are wide-ranging. Safety is enhanced because digital twins can detect anomalies that are invisible to the human eye or standard tools, such as micro-cracks in turbine blades that only show up as tiny shifts in vibration. Cost savings are significant as well: unplanned groundings can cost airlines tens of thousands of dollars per hour, so predictive insights can drastically reduce such unwanted occurrences. Maintenance operations also become more efficient, as crews no longer need to open panels “just in case” but can instead target their efforts where they are truly required. There is also an indirect benefit of digital twins, and that is making a positive contribution towards sustainability by extending component lifespans, reducing waste, and optimising fuel efficiency.

New operational methods bring new challenges

However, the implementation of digital twins does not come without challenges. Owing to the number of individual parts, today’s aircraft generate enormous amounts of data—sometimes terabytes per day—and managing, storing, and securing that data is a major hurdle. Interoperability across mixed fleets from different manufacturers adds complexity, and cybersecurity becomes a critical concern as real-time data links will always be vulnerable to nefarious attacks. Beyond this, the level of required technology requires a very substantial up-front investment in a complex infrastructure such as sensors and cloud platforms as well as AI modelling capabilities. Finally, the shift in operational procedures demands cultural change and new skill sets. Maintenance engineers must learn to work not only with wrenches and diagnostic tools but also with analytics dashboards and digital models, both of which require training and adaptation.

Despite these challenges, real-world applications are already proving the value of this new technology. Rolls-Royce has implemented digital twins in its TotalCare® service, monitoring thousands of engines worldwide which now enable the engine manufacturer to predict the need for part replacements with striking accuracy. Airbus has also launched its Skywise platform, which integrates fleet data into digital twin environments to provide airlines with real-time insights into operational performance and maintenance needs. GE Aviation has taken a similar approach with its engines, using digital twins to extend time-on-wing and improve fuel efficiency. These examples show that the technology is not a distant vision but a present reality that is currently shaping modern aviation.

What does the future hold for digital twins?

Looking ahead, digital twins are likely to become even more sophisticated and widespread. Airlines will increasingly manage digital replicas of entire fleets rather than individual components, optimising scheduling and routing decisions based on predictive maintenance data. Augmented reality will soon enter the hangar as well, with mechanics using smart glasses to view live overlays of digital twins directly on physical aircraft, highlighting areas that require attention. Robotics, combined with digital twin guidance, may eventually make semi-autonomous inspections and repairs possible. Regulatory authorities such as the EASA and the FAA are already beginning to define frameworks that will govern how digital twins can be validated and certified within maintenance processes, ensuring safety and reliability remain uncompromised.

The rise of digital twins represents a paradigm shift in how the aviation industry now approaches maintenance. By moving away from reactive and scheduled approaches and embracing predictive, data-driven decision-making, airlines and MROs are laying the groundwork today for a new era of safety, efficiency, and sustainability. While challenges remain, the trajectory is pretty clear: in the years to come, the digital twin will invariably become as essential to the hangar as the wrench or the torque meter. Maintenance teams will no longer have to predict whether or when a component might fail; they will know exactly when and be able to take appropriate proactive action.

Share this Article
Wednesday October 22, 2025
TrueNoord CEO Anne-Bart Tieleman (l) and Elysian co-CEO and co-founder Daniel Rosen Jacobson
Elysian, a pioneer in next-generation electric aircraft, has signed a collaboration agreement with regional aircraft lessor TrueNoord. The deal, announced during the European Regions Airline Association (ERA) General Assembly in Estoril, supports Elysian’s f... Read More »
Wednesday October 22, 2025
Norwegian Group
For the third quarter 2025, the Norwegian Group has posted a profit before tax (EBT) of NOK 2,891 million and an operating profit (EBIT) of NOK 3,071 million. The period also marked key milestones. The company paid its first-ever dividend in August and confirm... Read More »
Wednesday October 22, 2025
Wizz Air Airbus A321neo © AirTeamImages
Aviation Capital Group LLC (ACG) has delivered three new Airbus A321neo aircraft to Wizz Air. These aircraft are powered by advanced Pratt & Whitney GTF engines, known for their fuel efficiency and lower emissions. They mark the tenth, eleventh and twelfth... Read More »
Wednesday October 22, 2025
A CH-47F Block II conducts a flight at Redstone Test Center in Huntsville, Ala. © Boeing/Studio 51
The U.S. Army has advanced its heavy-lift modernisation plans with an order for nine Boeing CH-47F Block II Chinook helicopters. The two new contracts, worth US$461 million, bring the total number of Block II aircraft on order to 18. The latest awards, coverin... Read More »
Wednesday October 22, 2025
STS new station Vero Beach ©Shutterstock
STS Line Maintenance (STS), part of STS Aviation Group, has opened a new satellite station in Vero Beach, Florida (VRB). Operations will begin on December 1, with JetBlue Airways confirmed as the launch customer. Mark Smith, President of STS Aviation Group, sa... Read More »
Wednesday October 22, 2025
The deal paves the way for the development of up to six new narrow- and wide-body hangars across the airport estate © Teesside International Airport
A major deal has been agreed to support a multi-million-pound expansion of aircraft maintenance operations at Teesside International Airport. The move will create hundreds of skilled engineering jobs and boost the region’s growing aviation sector. Willis Avi... Read More »
Wednesday October 22, 2025
BCT hangar at East Midlands Airport (EMA)
BCT Aviation Maintenance, based at East Midlands Airport (EMA), has made a six-figure investment in new hangar tools and airside vehicles. The move prepares the company for a busy winter maintenance season. From October to December, BCT’s hangar will handle ... Read More »
Tuesday October 21, 2025
Korean Air and Archer executives on October 20th signing ceremony.
Korean Air and Archer Aviation (Archer) have signed an agreement to bring Archer’s Midnight eVTOL aircraft to Korea. The rollout will begin with government use and later expand to other sectors. As part of the deal, Korean Air plans to buy up to 100 Midnight... Read More »
Tuesday October 21, 2025
Acron Aviation has announced the acquisition of Honeywell’s Thermal Switches product line. This milestone marks the company’s second acquisition in just six months, following its launch as a standalone business in March 2025. The strategic purchase strengt... Read More »
Tuesday October 21, 2025
The agreement was announced in Hong Kong on the sidelines of the IATA World Sustainability Symposium
Airbus and the Cathay Group (Cathay) have announced a joint investment of up to US$70 million. The goal is to speed up the development of sustainable aviation fuel (SAF) across Asia and beyond. This marks another strong step towards cleaner, lower-carbon air t... Read More »
Tuesday October 21, 2025
TrustFlight
TrustFlight, a pioneer in aviation safety and compliance technology, has launched Smart Documents — a next-generation authoring platform that transforms how aviation organisations create, validate, and distribute operational documentation. The launch follows... Read More »
Tuesday October 21, 2025
Airborne Early Warning and Control aircraft rendering © L3Harris
L3Harris Technologies has secured a major contract to supply modified Bombardier Global 6500 aircraft for the Republic of Korea Air Force. These advanced airborne early warning and control (AEW&C) jets will enhance national defence and surveillance. The pr... Read More »
Tuesday October 21, 2025
Arlanda Airport
Stockholm Arlanda Airport is taking European aviation into a new era. Swedavia and Luftfartsverket have jointly introduced Established on RNP (EoR), a concept that enables aircraft to perform curved approaches more often. It is the first of its kind in Europe,... Read More »
Monday October 20, 2025
Rendering of the A350-900 in IndiGo livery
IndiGo, India’s largest airline, has finalised a firm order for 30 Airbus A350 aircraft. This deal converts a memorandum of understanding signed in June into a confirmed contract. As a result, IndiGo’s total A350 orders now stand at 60. The agreement marks... Read More »
Monday October 20, 2025
Logistic hu
Skyparts, the original equipment manufacturer (OEM) trade desk of Acron Aviation, has announced a strategic channel partnership with Setna iO. Setna iO is well known for distributing used serviceable material (USM) and OEM aircraft parts. This agreement drives... Read More »
Monday October 20, 2025
SIA Engineering Philippines facility
AerFin, the aviation asset specialist, has announced the successful completion of a 2017 Airbus A320neo disassembly. The project was carried out by SIA Engineering Company (SIAEC) at its Philippines facility, SIAEP. This milestone marks several firsts for the ... Read More »
Monday October 20, 2025
The agreement between ATR and ATAVIS will support 26 ATR 72-600 aircraft operated by CANAIR and NAYSA © ATR
ATR, the regional aircraft manufacturer, has signed a global maintenance agreement (GMA) with ATAVIS, Binter’s technical procurement and supply chain arm. The agreement will support 26 ATR 72-600 aircraft operated by CANAIR and NAYSA. The GMA is ATR’s flag... Read More »
Monday October 20, 2025
Saska Gerasimova
Chapman Freeborn, the global air charter specialist, has appointed Saska Gerasimova as its new Group CEO. She officially takes over on October 20, succeeding Eric Erbacher, who moves into a new position as Chair of the Chapman Freeborn Holdings Board. This lea... Read More »
Monday October 20, 2025
Fiji Airways
Wright International, part of the global MRO group FL Technics since 2020, has secured approval from the Civil Aviation Authority of Fiji (CAAF). Following this milestone, the company has launched a new partnership with Fiji Airways. Under the agreement, Wrigh... Read More »
Monday October 20, 2025
Embraer and Mahindra Group forge a strategic alliance to introduce the C-390 Millennium to India © Embraer
Embraer Defense & Security and Mahindra Group have taken a bold step towards India’s Atmanirbhar Bharat vision. The two companies have signed a Strategic Cooperation Agreement (SCA) to advance the C-390 Millennium aircraft for the Indian Air Force’s Me... Read More »
ajw avitrader

2026 MEDIA KIT

VP Sales & Business Development Americas
Tamar Jorssen
tamar.jorssen@avitrader.com
Phone: +1 (778) 213 8543
VP International Sales & Marketing
Malte Tamm
malte.tamm@avitrader.com
Phone: +49 (0)162 8263049

Subscribe to the most widely accepted news source in the aviation industry!


Free Daily, Weekly and MRO Publications delivered to your Inbox!
News Alerts, Editorials, Marketplace, Executive Interviews +more

Select publications:

*we respect your privacy and AviTrader will not share your email address to any 3rd Parties.