By Suzanne Kubler

The wings of the M437 technology demonstrator took flight in August 2024, showcasing how Northrop Grumman’s Digital Pathfinder process is transforming aerospace innovation. By combining an advanced digital ecosystem with cutting-edge manufacturing techniques, Digital Pathfinder accelerates reschedules, reduces costs, and minimizes rework, highlighting its potential to reshape future programs. 

Developed over just two years, Digital Pathfinder exemplifies Northrop Grumman’s broader digital transformation, seamlessly connecting employees, customers and suppliers through a fully connected digital thread.

The approach integrates the entire product lifecycle, enabling real-time collaboration, reducing risks and enhancing quality. Its success was validated through the rapid design, build and flight of the wings for Scaled Composites’ M437 demonstrator aircraft — one of many ways the company is leveraging digital innovation to drive efficiency and performance across programs.

There are 10 key efficiencies achieved through Digital Pathfinder:     

1. Laying the Foundation 
   
   Digital Pathfinder launched in April 2022 with a clear goal: fully integrate Northrop Grumman’s digital tools to create a continuous digital thread. “It was our primary focus. There were no shortcuts,” said Director Sarah Beaudin.
   
   
2. Building on Proven Success 
   
   Lessons from the B-21 program formed the backbone of the Digital Pathfinder process. Advanced digital simulation environments allowed test pilots to evaluate aircraft performance in highly accurate simulated settings. “These real-world experiences are the foundation for Digital Pathfinder and validate the high-fidelity models from start to finish,” said Chief Engineer Gus Taksa. 
     
3. Using Tools in New Ways 
   
   Northrop Grumman’s connected digital thread boosted overall performance, said Sarah Saller, an aeronautical engineer. “We pioneered new digital connections utilizing the tools in different ways that hadn't been done before,” she said.   
   
   
4. Minimizing Rework   
   
   The process achieved engineering rework rates below 1 percent, a dramatic improvement over the industry standard of 15-20 percent. Manufacturing rework decreased by more than 50 percent. “It’s amazing what’s possible when you fully embrace digital,” Sarah Beaudin said.
      
5. Staying on Schedule 
   
   Despite the complexity of the M437 wings, the project experienced less than 2 percent schedule erosion. Systems Engineering Manager Loubens Decamp attributed this to clear communication and the ability to pivot quickly all made possible by the enhanced digital thread. “By designing for change upfront, the savings we found on the back end were tremendous,” Loubens said.
     
6. Collaboration is Key   
   
   Insights from design, manufacturing, global supply chain, sustainment and the customer were integrated from the start. “Digital Pathfinder’s collaboration was like nothing I’ve seen in my 25-year career,” Gus said.
      
7. Partnering with the Customer 
   
   A cooperative research and development agreement (CRADA) with the U.S. Air Force fostered close collaboration between the Digital Pathfinder team and the customer. “Seeing different stakeholders come together with the customer to talk about the problems and challenges we normally see in a program was amazing,” Gus said.
      
8. Revolutionary Tools 
   
   Additive manufacturing (AM) techniques, including Scalable Composite Robotic Additive Manufacturing (SCRAM), and Directed Energy Deposition (DED) were key to the program’s success. The DED process produced the primary titanium structure of the wing, marking the first known defense application of continuous fiber composites AM. “We’re seeing a 30 percent reduction in cost and schedule timelines for these parts, compared to traditional processes. The result: We can get the right products to the warfighter faster and safer,” Sarah Beaudin said.
      
9. FAST Assembly 
   
   The Feature Aligned Self-Locating Technique (FAST) enabled rapid, prefabricated assembly. “Components arrive ready to assemble, significantly reducing costs and lead times,” said Eric Barnes, a Northrop Grumman Manufacturing Fellow.
       
10. Risk Reduction 
    
    One of the greatest challenges in X-plane development is mitigating risk, which the Digital Pathfinder process tackles. “The experience gained being a part of this team is unmatched,” Sarah Saller said. “We will now take this digital expertise to current programs as well as future efforts. You simply can't put a price tag on that.”