How Digital Twins Are Reengineering Aerospace from the Ground Up

Discussion with Carlos Castro

With nearly two decades of experience across engineering, consultancy, and business development in aerospace, Carlos Castro is at the forefront of reshaping aircraft design through advanced digital tools. Now returning to PACE Aerospace & IT, part of the TXT Group, he brings a unique cross-functional lens to the evolving field of digital twin technologies. In this article, Carlos unpacks how digital twins, paired with integrated tool sets like Desmo and Missions, are revolutionizing aircraft development, sustainable aviation, certification pathways, and aftermarket services.

Engineering Integration: Unlocking System-Level Co-Design

Digital twin innovation is moving the industry from isolated design methods to a fully integrated, system-level design environment. But what is a digital twin? Imagine a highly detailed, constantly updated virtual copy of a physical object, like an airplane. That's a digital twin. For Carlos, this shift is enabled by platforms like Desmo and Missions, which unify previously isolated design processes into one coherent digital thread.

Carlos emphasizes that, while individual modeling tools remain effective within their specific domains, challenges emerge when trying to connect them. “Each modeling tool excels within its designed domain but integrating them into a cohesive digital twin environment remains complex”, Carlos explains. “The ultimate challenge lies in defining durable interfaces that connect tools with varying fidelity levels and domain focuses”.

Desmo addresses this challenge by integrating aerodynamics, propulsion, structures, and systems architecture into one early-phase design platform. Its ability to connect with other tools, including engine design and Model-Based Systems Engineering (MBSE) software, which helps manage complex system designs, enables a level of collaboration never before possible. “In a mature digital thread, we are connecting preliminary design tools like Desmo with tools from engine manufacturers”, he adds, “allowing aircraft airframe and engine design to happen in a connected loop”.

This interoperability supports a more responsive and realistic design process. It also allows engineering teams to test how design changes affect downstream performance and cost. According to Carlos, connecting these tools unlocks powerful insights. “Desmo and Missions can be connected, allowing for performance and economic calculations of aircraft designed in Desmo for specific scenarios in Missions”.

Digital Twins in Preliminary Design: Beyond the Static Aircraft

Carlos believes digital twins are fundamentally changing how aircraft are evaluated in the earliest phases of development. Instead of just running static simulations, digital twins allow teams to analyze how aircraft perform in real-world use. For example, they can evaluate how different weather conditions or flight routes impact fuel consumption or maintenance needs.

He notes that today’s design tools are still largely compartmentalized, but the shift toward deeper data integration is well underway. “Current practices involve calculations and simulations within or across a few tools, but we expect improvements through increased data availability and potentially AI assistance”, Carlos describes.

This evolution is especially relevant for next-generation aircraft, such as hybrid or fully electric designs. Tools, like the ones discussed in previous paragraphs, allow teams to model not just configuration performance, but also energy usage, maintenance cycles, and total cost of ownership. “Digital twins help simulate not just static performance metrics”, he explains, “but dynamic mission scenarios and lifecycle behaviors, such as fuel burn, maintenance costs, or charging cycles”.

The real breakthrough, however, comes from making this data-driven feedback continuous. That’s where integration between tools becomes critical. “Digital twins provide a continuous, data-driven feedback loop between design assumptions and real-world performance expectations”.

Looking ahead, Carlos sees AI as an important accelerator. “With more data and AI, we may be able to derive calculation methods for novel aircraft designs without traditional prototyping”, he says.

Certification, Maintenance, and the Future of Lifecycle Digitalization

The future of digital twins, Carlos argues, goes far beyond the design phase. He sees them becoming central to certification, fleet management, and maintenance in the next five to ten years.

This transition is already gaining traction, particularly among companies designing novel aircraft types. “Digital twins are likely to evolve from engineering support tools into core enablers of certification, operations, and lifecycle management”, Carlos predicts. “Regulatory bodies may begin to accept digital twin models as part of the certification process—especially for novel aircraft types and autonomous systems”.

For this shift to succeed, reliability is critical. Carlos stresses that while today’s tools are powerful, computing constraints still limit how much can be simulated. “Reliability is key. We’re still limited by computational resources”, he notes. “But as we integrate requirements, design, and operational data, digital twins will help us predict failures and optimize maintenance”.

This same data infrastructure will reshape how operators think about maintenance. Instead of following rigid schedules, they’ll rely on insights drawn from historical and real-time data. “Digital twins will help improve operations by analyzing past data and best practices to inform future operations”, outlines Carlos. “They’ll allow for early detection and prediction of issues”. This predictive model promises to reduce downtime, extend aircraft life, and improve overall fleet reliability.

Strategic Positioning in a Software-Defined Aerospace Industry

As software becomes the backbone of aerospace innovation, PACE is evolving its identity from product provider to transformation partner. Backed by TXT Group, the company has strategically acquired niche solutions that expand its value proposition across design, operations, and training.

Carlos notes that this diversified approach reflects how aerospace itself is changing. “TXT Group and PACE have acquired niche companies with specific products. Our suite of tools supports the digitalization of aviation companies”.

At the same time, PACE is investing in research-driven development. The company participates in major European initiatives like Clean Aviation, ensuring its products align with future sustainable flight technology. “We participate in numerous R&D programs in Europe, partnering with OEMs (Original Equipment Manufacturer), suppliers, SMEs, and national research institutes”, Carlos describes.

This R&D-led model gives PACE the flexibility to respond to both long-term trends and short-term client needs. The ability to roll out custom features in just a few months has become a competitive differentiator.

Sustainable Aviation: Digital Tools for a Greener Sky

The pressure to decarbonize aviation is intensifying, and digital twin technology is proving essential in the search for viable solutions. At PACE, sustainability is not a marketing tagline—it’s built into the very architecture of their tools.

“Tools like Desmo (formerly APD and SysArc) are already used to simulate sustainable aircraft concepts like electric, hybrid-electric, SAF-powered, and hydrogen fuel cell designs”, Carlos recalls. Today, these capabilities are expanding through collaborative R&D programs with OEMs and research bodies like DLR and ATI.

Digital twins allow engineers to simulate new propulsion architectures, analyze energy consumption, and evaluate environmental impacts long before a single component is built. “Desmo, being focused on preliminary design, needs to interface with more detailed analysis tools, especially for novel propulsion systems like distributed propulsion and its aero-propulsive interaction effects”, mentions Carlos. This speeds up innovation while mitigating the risks associated with unproven technologies.

PACE’s commitment to open APIs and modular integration further ensures that their tools can plug into broader sustainability ecosystems. From lifecycle emissions tracking to noise footprint analysis, the company’s digital twin platforms are helping customers explore cleaner, more viable pathways for flight.

Final Thoughts: Digitalizing with Purpose

As aerospace continues its shift toward data-driven, AI-enhanced, and software-defined systems, Carlos Castro offers a clear, actionable framework for executives preparing to lead through this transformation:

Digitalize with purpose: Focus on areas where digital twins and digital threads offer tangible business or technical value. Avoid technology for technology’s sake.

Adapt to future workflows: Embrace emerging tools like AI, integrated model-based systems, and interoperable platforms to remain agile and competitive.

Invest in enabling platforms: Solutions like Desmo and Missions aren’t just tools, they’re strategic assets for speed, reliability, and innovation in aerospace design and operations.

“We need to stop thinking of design, certification, and operations as separate steps. With the right tools and data, they can all speak to each other—and that’s where the real value begins”, Carlos concludes.