As defense electronics grow more complex, Siemens’ Jean Piguet reveals how Designcenter’s digital twin creates a single source of truth, from requirements to manufacturing.
Aviation Week: What changes over the last 10-20 years have made digital tools like Designcenter so important?
JP: The complexity of defense electronics systems has increased dramatically. Platforms that used to be mostly mechanical now have more sensors, more computer-driven capabilities, and the number of Line Replaceable Units (LRUs) has surged. At the same time, we see intense cost pressure and shrinking deadlines.
We are being asked to develop incredibly complex systems in record time on tighter budgets. This has driven a massive digital transformation journey—not just shifting the mechanical CAD aspect but completely evolving the broader design process. It used to be document-centered; today, it is fully digital.
AW: How has that evolution led to a comprehensive digital twin?
JP: A comprehensive digital twin is the natural response to rising complexity because a document-centered approach couldn’t survive the sheer scale of modern engineering
From Siemens’ perspective, Designcenter and Capital are at the heart of that transformation. They author all the critical pieces of mechanical, electrical and electronic information and connect them with the broader Siemens Xcelerator portfolio. They track every change, analyze how those changes ripple through both electrical and mechanical domains, and serve as a single source of truth.
Because of this deep integration, teams no longer have to rely on physical prototypes to spot clashes or design flaws. You can visualize complex systems—like multi-redundant fighter jet wiring—in a shared 3D environment, dramatically speeding up component placement and bundle routing while ensuring teams are right the first time.
For instance, one customer showed us a fighter jet that required three levels of electrical redundancy. In a traditional 2D electrical diagram, managing that level of wiring complexity can become a confusing nightmare. But seeing how it looks in the 3D world—connecting the electronic and mechanical CAD—restores clarity.
One of the advantages of the full digital twin, especially in the context of Designcenter, is being able to handle very, very large assemblies. I mentioned the increasing level of complexity, we are talking hundreds of thousands of components within a product.
AW: What domains does Designcenter cover?
JP: Designcenter offers over 140 integrated, optional modules accessible via value-based licensing that span the entire product lifecycle.
It goes far beyond basic wiring. For example, with our specialized sheet metal add-on, engineers can design parts that automatically bake in manufacturing constraints right from the start before sending that data downstream. Another module handles heavy-duty mass roll-up and inertial properties calculations—which sound technical, but if you’re developing a satellite, getting those numbers wrong means your multi-million-dollar spacecraft isn’t making it into orbit. We also cover advanced domains like corrosion analysis and composite part design. Whatever the engineering challenge, Designcenter has a module to solve it.
AW: How does the digital thread work within Designcenter?
JP: The digital thread is the chain of relationships that gives continuity. It runs completely uninterrupted from end to end, starting at the very beginning with initial requirements and system models, flowing directly into defining complex electrical diagrams, and then transitioning seamlessly into the mechanical world for routing. From there, that same stream of information powers everything downstream, stretching all the way from formboards and flattened harnesses down to final manufacturing operations. Because that thread is never broken, information is never lost in translation between teams, eliminating costly shop-floor surprises before they ever happen.
AW: How challenging is switching over to Designcenter from legacy systems handling military electronics?
JP: Switching over follows Siemens’ open philosophy, which includes multi-CAD support. You can import data from different legacy tools, work directly on that geometry, and add intelligence to it. For example, if a model you receive already has a bunch of holes or ribs, you can use that information and manipulate the geometry directly within Designcenter, regardless of its origin.
We have been through this migration process with many customers, so it is battle-proven. We offer dedicated tools for migrating and directly translating data. A great recent example is Bombardier, which migrated to our environment for new product development and has had great success reusing their legacy data seamlessly.
AW: How will Designcenter incorporate AI technology to aid the design of defense electronics?
JP: AI transforms Designcenter from a system that records engineering knowledge to one that helps engineers apply it. We approach AI across three distinct levels.
First, we have AI tools to assist the individual engineer day-to-day.
Second, we have implemented AI for the process, automating those tedious, repetitive tasks that waste so much of an engineer’s valuable time.
Finally, there is AI for creation. Designcenter is built as an open platform with robust APIs that connect directly to LLMs and other advanced tools, allowing our customers to unlock next-level AI innovations. But we are moving carefully and responsibly: keeping a strict human in the loop, aggressively protecting customer intellectual property, and staying securely within customer boundaries. The future of AI in engineering is bright, but it’s anchored in trust and control.
