The functionality of the US military, which is bigger than almost any organization on earth, depends on getting many decisions right and not just what pertains to operations. Good decision-making is fundamental across the board, including building new systems and sustaining legacy platforms.

Historically, though, figuring out what works and what doesn’t has been an inexact process with plenty of trial and error. But now, the integration of AI and digital twins into defense manufacturing is taking some of the guesswork out of the equation.

Digital twins and AI provide new layers of mission-critical information to help senior leaders and their direct reports do their jobs more effectively. These technologies involve building virtual models for what is essentially a series of high-tech rehearsals. Among the benefits are shortening development cycles, reducing costs with precision, and delivering future-proof readiness through continuous learning. In an increasingly networked battlefield, this technology also helps commanders turn data into actionable analysis, enabling troops to react quickly to the unpredictability of war and the twists and turns of bureaucracy.

Digital twins and AI herald a new era that acquisition officers, program managers, and intelligence agencies must adapt to quickly in order to stay in front of the evolution of the latest threats, particularly those from asynchronous warfare. Realizing the benefits starts with understanding digital twins and AI.

Digital Twins and AI Shorten Design-to-Deployment Timelines

Engineers use digital twins and AI to design, simulate, and stress-test components or systems in parallel, rather than sequentially, to get as close to real-world outcomes as possible. This approach accelerates the pace of decisions across the DoD by replacing legacy test-and-learn and bureaucratically laden methods with something more agile.

The process also identifies bottlenecks early. AI-driven analysis derived from digital twin data reveals potential failures and highlights inefficiencies long before systems get to the factory floor for physical manufacturing. In preventing these issues, the technology saves time and money up front.

Later in the development lifecycle, digital twins and AI continue to deliver improvements, helping defense and intelligence agencies by providing predictive maintenance insights, which leads to tighter, more effective, and affordable supply chains. The Army, Navy, and other branches are already implementing these models to drive improvements in technology and operations.

Outside of a manufacturing environment, digital twin technology joins with AI to boost mission planning and operations. For example, it can model scenarios involving extreme conditions and contested logistics, such as electronic warfare. These simulations give commanders confidence in the readiness of the new systems before committing to production, which is fraught with the potential of wasting billions of dollars.

The sources of data for DoD digital twin models are voluminous, so the idea is to integrate all those systems—from sensor feeds, weather updates, and threat intelligence to equipment status—into a coherent whole. This continuous feedback loop enables rapid adjustments to production lines, tactical decisions, and daily operations, impacting hundreds of thousands of individuals. The goal is to provide leaders with increased foresight and insight into their vital responsibilities.

Reduce Acquisition Costs While Increasing Precision

Digital twins and AI may not be able to reverse historic examples of program cost overruns, but they can still play a role in the continuous improvement of the acquisition and manufacturing processes. By continuously monitoring systems, digital twins can identify inefficiencies like bottlenecks or quality deviations and sound the alarm for immediate adjustments, reducing rework and shortening cycle times.

Digital twins simulate the flow of materials and supplies to a production line at a granular level. This helps promote techniques like just-in-time inventory, thus saving money by optimizing procurement and reducing waste. These are typically the items that lead to problems with overruns and result in costly adjustments in order to adapt to changing uses of expensive defense-grade materials and components.

Introducing greater precision in product leads to fewer defects and failures in the field, which allows for increased operational tempo and improved mission reliability. It also just makes sense, as greater predictability helps remove costs tied to repairs and recalls.

The real breakthrough in the digital twin ecosystem is the ability to put acquisition, production, and operational data onto a common platform, where decision-makers across the institution can take real-time inputs and forecast costs and performance, making everyone in the system smarter and lowering risks.

Future-Proof Readiness Through Continuous Learning

Creating system-wide digital twins enables defense systems to adapt dynamically. The information and insights that they provide mean the entire force can evolve in almost real time when faced with new mission demands. At a time when unconventional threats are multiplying, anything that enables a smarter, faster, and more resilient force is critically important. It happens sequentially, consecutively, and dynamically. For instance, machine-learning algorithms analyze live data to spot unusual patterns or system degradations early.

Defense planners can test new tactics or equipment in a living digital environment that learns from each mission, providing lessons that are particularly relevant in complex or contested environments. The technology can also be used to develop and execute immersive training, leading to continuous learning and adaptations. The training is fueled by integrating battlefield data, thus enabling personnel to rehearse against the most current threats and tactics.

As digital twins learn more from every deployment and exercise, they inform design and procedural upgrades, making systems smarter, faster, and more resilient over time.

Team Up with Sumaria Systems on Digital Twins and AI

The ideal outcome for any project is to deliver on time, on budget, and with consistently high quality. Digital twins and AI can move defense and intelligence agencies closer to capturing these pillars of success. While they provide tangible near-term benefits, such as lower costs, they also provide intangibles, such as opening the door to greater learning, flexibility, and adaptability.

With a four-decade history supporting government, defense, and intelligence agencies in systems engineering, Sumaria is ready to serve as your partner in capturing the benefits of digital twins and AI.

Digital twins and AI bring real-time foresight and control into defense manufacturing. Whether building new systems or sustaining legacy platforms, these technologies empower DoD leaders to reduce cost, mitigate risk, and ensure production resilience at scale. Contact us for help with the strategic integration of advanced technologies and methods to streamline and optimize the development, maintenance, and operation of systems and infrastructures.