In today’s rapidly evolving industrial landscape, businesses are increasingly challenged by the growing complexity of their products. From Aerospace & Defense to Transportation & Mobility, every sector is experiencing a shift toward more sophisticated systems. This complexity demands a new approach to engineering. It requires integrating digital engineering, systems engineering, MBSE (Model-Based Systems Engineering), and Virtual Twin technologies to streamline design, simulation, and implementation for customers.
We recently had the opportunity to speak with Danny Alcini, Senior Sales Executive Strategic Technology Consulting (STC), an Arcfield Company, about how companies are overcoming these challenges and implementing next-generation engineering solutions.
Understanding the Challenges in Modern Product Design
According to Danny, one of the biggest challenges facing engineers today is the ubiquity and complexity of products. “All products are becoming complex,” he explains, “and this trend isn’t limited to aerospace or defense, it’s now penetrating automotive and mobility sectors.”
The traditional approach to product design, rooted in early CAD practices, often separates design and simulation processes. Engineers would design a product, then simulate its performance, and finally test it, only to often discover issues too late in the development cycle. This sequential approach can be costly and inefficient.
The Role of Digital Engineering and MBSE in Overcoming Complexity
STC has been at the forefront of helping organizations adopt digital engineering strategies that unify design and simulation from the very beginning. By leveraging ModSim (Modeling and Simulation) in combination with MBSE, companies can now define system requirements, test products virtually, and validate designs using a unified model. This ensures that designs meet user needs and functional requirements before physical prototyping begins.
“ModSim allows you to start testing immediately,” says Danny. “And MBSE ensures that the entire system’s behavior, constraints, and interdependencies are captured in a model from the outset. This sets your entire program on the right path from day one, reducing risks, costs, and time-to-market.”
Digital engineering solutions like these are not just about efficiency—they fundamentally change the way engineers approach product development. Instead of point solutions or fragmented tools, organizations are moving toward integrated digital platforms that connect all aspects of design, simulation, verification, and MBSE-driven system modeling.
Systems Engineering Expertise: A Key Differentiator
At STC, over 200 practitioners bring deep systems engineering and MBSE expertise across multiple industries. This experience allows STC to tailor implementations for each client, ensuring successful integration of digital product engineering solutions. By coordinating disparate teams and processes, companies can achieve a full authority digital engine control over their projects, meaning complete oversight of design, simulation, and performance outcomes.
This approach emphasizes the importance of digital engineering systems that combine the strengths of various tools under a single platform. Rather than relying on multiple vendors and point solutions, companies can now achieve exponential gains in efficiency by adopting integrated solutions like CATIA. These solutions provide seamless collaboration across design, manufacturing, simulation, and MBSE workflows.
We have to do better. And to me, that is the reason that the platform exists.
– Danny ALCINI, Senior Sales Executive
Virtual Twin Technology: Bridging Design and Reality
A central component of modern digital transformation in engineering is the use of Virtual Twin technology. It is a virtual replica of a physical product or system that allows engineers to simulate, monitor, and optimize performance in real time.
Danny explains that, traditionally, design and simulation data used different models, creating inefficiencies and risks. With Virtual Twins, and especially when combined with MBSE models, these processes are unified. Engineers can test structural integrity, rigidity, and functionality virtually, reducing the likelihood of costly errors during manufacturing.
The benefits of Virtual Twin engineering extend beyond initial design. By continuously monitoring and updating the Virtual Twins throughout a product’s lifecycle, companies can improve maintenance. Leveraging MBSE to manage system-level interactions also helps predict failures. Together, these practices enhance overall system performance, delivering tangible value to both manufacturers and end-users.
Practical Advice for Implementing Digital Engineering Solutions
For organizations exploring new implementations of CATIA or other digital engineering tools, Danny offers practical guidance:
- Choose integrated platforms over point solutions – While it may be tempting to select best-in-class tools for specific tasks, the real gains come from platforms that unify design, simulation, verification, and MBSE models.
- Focus on full lifecycle efficiency – Integration allows teams to capture efficiency across the entire program, from initial concept to final product delivery.
- Tailor solutions to your needs – No two projects are identical. Customizing the approach ensures that all user needs and requirements are met.
- Adopt ModSim and MBSE practices early – Starting simulation and model-based system design alongside conceptual design helps identify issues sooner, saving time, costs, and reducing risk.
By following these principles, companies can achieve a smooth transformation. This transformation delivers measurable results in terms of efficiency, product quality, and innovation.
The Broader Impact of Digital Product Engineering
Digital engineering, MBSE, and Virtual Twin solutions are more than just technical advancements, they represent a strategic shift in how companies approach engineering challenges. Organizations that embrace these tools can:
- Streamline asset by consolidating data and workflows.
- Enable digital product engineering with real-time simulation and system modeling.
- Implement a robust digital engineering strategy that aligns with business goals.
- Reduce costs and time-to-market through digital model-based engineering and MBSE-driven processes.
These advantages are critical for industries where complexity is increasing and the margin for error is shrinking. By leveraging digital twin technologies, MBSE, and integrated digital engineering tools, companies are not only improving product outcomes, they are transforming their engineering culture and capabilities.
Conclusion: Leading the Future of Engineering
Danny Alcini’s insights underscore a key truth: modern engineering success depends on adopting digital engineering solutions. These solutions combine systems engineering expertise, MBSE practices, Virtual Twin technology, and integrated platforms. Companies that embrace these strategies can overcome complexity, meet user needs, and achieve unprecedented efficiency across their programs.
From defense to automotive, the future of engineering lies in fully integrated digital transformation. This is where design, simulation, system modeling, and validation occur in harmony. As Danny emphasizes, the organizations that lead this shift will set the standard for innovation, efficiency, and operational excellence. They will shape how success is defined in the 21st century.
By prioritizing digital engineering, leveraging ModSim, integrating MBSE practices, and combining systems engineering best practices, companies can confidently navigate the challenges of modern product development. This approach enables them to deliver exceptional value to their customers.
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FAQ
What is the definition of digital engineering?
It is an integrated approach to product development that combines design, simulation, and verification in a unified digital environment. It allows organizations to streamline processes, thereby reducing costs, while also ensuring that complex products meet performance and user requirements even before physical prototyping begins.
What is the role of a digital engineer?
A digital engineer applies its strategies, tools, and platforms to design and validate products. Their role involves unifying workflows across systems engineering, simulation, and manufacturing, ensuring that projects run efficiently and deliver reliable outcomes in increasingly complex industries.
What are digital engineering tools?
Digital engineering tools are software platforms, such as CATIA and ModSim, that integrate design, simulation, system modeling, and verification. These tools enable collaboration across teams, support model-based engineering practices, and allow engineers to address complexity throughout the product lifecycle.
What is Model-Based Systems Engineering (MBSE) and why is it important?
MBSE (Model-Based Systems Engineering) uses models to define, design, and validate systems, replacing traditional document-heavy approaches. It is important because it captures requirements, constraints, and system behaviors in a unified model. As a result, it reduces risks, while simultaneously accelerating development and ensuring that complex systems meet user needs from day one.
How does Virtual Twin technology support digital engineering?
Virtual Twin technology creates a virtual replica of a physical product or system that can be simulated and monitored in real time. In digital engineering, this supports better design decisions, continuous validation, predictive maintenance, and improved performance throughout the product lifecycle.