SBIR-STTR Award

The development of a digital twin for the B-52H Stratofortress aims to transform the maintenance, operation, and modernization of this legacy aircraft, ensuring its readiness and efficiency through 2050 and beyond. This project, led by Beast Code, leverages advanced data aggregation technologies to create a comprehensive yet lightweight digital representation of the B-52H, integrating 3D models and other system models together with system metadata and authoritative acquisition source material to provide a one-stop shop for end-users. The Phase I effort focuses on establishing the foundational elements necessary for this digital twin, including defining the system concept, conducting a feasibility study, and proposing a detailed plan for further development. The primary objectives of Phase I include developing a detailed understanding of the B-52H's operational, maintenance, and modernization needs, and outlining the architecture for integrating the digital twin with existing and future systems, including simulation environments. Additionally, it involves assessing the technical feasibility of creating a digital twin, considering data availability, technical documentation, and 3D models, and identifying potential challenges, risks, and mitigation strategies. Finally, Phase I aims to develop a comprehensive plan for data collection, model development, integration, and validation, defining the scope of the minimum viable product (MVP) for the digital twin and establishing a realistic project timeline. Beast Code's approach will utilize its data visualization software, Beast Core, which is already accredited on DoD Platform One's Iron Bank repository up to the IL-5 Controlled Unclassified Information (CUI) level. This technology enables lightweight visualization, flexible deployment across cloud and on-premises environments, and optimized file sizes, ensuring that the digital twin can be accessed and maintained even in environments with limited connectivity. The anticipated results of Phase I include a detailed system concept document, a feasibility study report, and a comprehensive project plan for the digital twin's development. These outcomes will lay the groundwork for Phase II, where the digital twin will be refined, validated, and integrated with new equipment for extensive testing. The ultimate goal is to create a well-defined deliverable prototype that can simulate various operational scenarios and support the full lifecycle of the B-52H. By establishing a strong foundation in Phase I, this project aims to revolutionize the maintenance and modernization of the B-52H, ensuring its operational effectiveness and extending its service life. The digital twin will serve as a model for similar efforts across other platforms, supporting the broader goals of the Air Force's digital transformation and modernization initiatives.

Beast Code proposes to deliver a full aircraft-level digital twin of the B-52H Stratofortress, built using legacy 2D technical data, NAIR CAD, LiDAR, and photogrammetry scans, and deployed within Beast Core, an extensible visualization platform already operational across multiple DoD programs. This Phase II effort builds upon a completed Phase I pilot that demonstrated the feasibility of converting legacy data into structured, interactive 3D geometry with linked technical documentation and metadata overlays. The project will be executed in three sequential phases—Discovery, Production, and Refinement—spanning a 12-month period. All major system categories (Airframe, Propulsion, Electrical, Avionics, etc.) will be represented in the twin, organized according to USAF data structures and configuration. Key technical goals include validating geometry, integrating system metadata, linking authoritative documentation, visualizing sustainment workflows, and preparing for MBSE/PLM alignment through future integrations with CAMEO and Teamcenter. The Phase II digital twin will be deployed in a secure IL5 GovCloud environment with completed RMF documentation in pursuit of an Authority to Operate (ATO). A new research task has also been added to investigate simulation-driven approaches for platform longevity and airworthiness evaluation in future phases. This will include a third-party partner technical whitepaper on candidate simulation tools and visualization approaches. All development will be modular and scalable, ensuring the final delivery is immediately usable for sustainment stakeholders and extensible into a Phase III production environment. Throughout the effort, government subject matter expert (SME) validation will guide technical decision-making, data fidelity, and functional utility. Final deliverables include the digital twin environment, all structured data, a complete set of user documentation, and a government-reviewed SME validation report.