Immersive technologies in aerospace: From innovation to necessity

Not long ago, using virtual reality to train aerospace technicians or augmented reality to assist in maintenance felt like science fiction. Today, immersive technologies are soon to become essential.

The aerospace and defense industry is under pressure. Airlines are struggling to meet surging travel demand, supply chain disruptions are delaying production, and a retiring workforce is creating a skills gap. At the same time, sustainability mandates are pushing manufacturers to improve efficiency while reducing waste.

Simply hiring more workers or relying on traditional methods won’t be enough. To train faster, streamline production, and enhance collaboration, companies need new solutions—and immersive technologies are filling the gap. Augmented reality (AR), virtual reality (VR), and extended reality (XR) are already transforming how teams learn, work, and innovate.

Once considered experimental, these tools are now enterprise-ready and scalable. Companies that embrace them today will lead the next era of aviation.

What is immersive technology and why does it matter?

Immersive technologies—augmented reality (AR), virtual reality (VR), and extended reality (XR)—merge digital and physical worlds, transforming how aerospace companies train employees, design aircraft, and collaborate. Once seen as experimental, these tools are now scalable and practical, solving some of the industry’s biggest challenges.

• Augmented Reality (AR) overlays digital information onto the real world, helping technicians see schematics, step-by-step assembly instructions, or system diagnostics in real-time.
• Virtual Reality (VR) creates fully simulated environments where pilots, engineers, and technicians can train or test designs without physical aircraft.
• Extended Reality (XR) is an umbrella term covering both AR and VR, along with mixed-reality applications that blend real and digital elements.

Aerospace is under growing pressure to produce more, train faster, and operate with greater precision. A retiring workforce is creating a knowledge gap just as aircraft systems become more complex, making traditional training and manufacturing methods harder to sustain. At the same time, rising production demands leave little room for inefficiencies or delays. Immersive technologies are becoming essential tools in this environment, allowing companies to modernize training, refine manufacturing processes, and improve collaboration across global teams. As these tools become more advanced and widely adopted, they are shaping the future of how aircraft are built, maintained, and operated.

Misconceptions about immersive technologies

There’s a common assumption that immersive technology is about replacing human expertise with automation. In reality, it’s about enhancing collaboration, efficiency, and safety by putting better tools in the hands of experts.

• It doesn’t replace human intuition—it augments it. Pilots, engineers, and technicians still rely on expertise, but immersive tools provide deeper, faster, and more effective training than traditional methods.
• It’s not just for training: While often associated with workforce development, immersive technology also improves design visualization, remote troubleshooting, and real-time collaboration across supply chains.
• It’s already proving its value: Early adopters are seeing real cost reductions from shorter learning curves, fewer errors, and faster approvals in manufacturing and sales.

Immersive technology is no longer something aerospace companies can afford to wait on—it’s a strategic advantage that will define the industry’s next era.

How immersive technology makes A&D training more effective

For decades, aerospace training has relied on a combination of classroom instruction, hands-on mentorship, and access to real aircraft. But as fleets grow more complex and skilled technicians become harder to find, traditional methods are proving too slow, too expensive, and too difficult to scale. The industry needs a faster way to train the next generation of workers—without grounding aircraft or pulling seasoned experts away from critical operations.

Immersive technologies are stepping in to fill this gap. AR, VR, and XR are transforming training by creating realistic, repeatable learning environments that accelerate skill development while reducing costs. A trainee can now enter a fully simulated cockpit, interact with controls, and practice emergency procedures long before stepping into a real aircraft. Maintenance crews can rehearse engine repairs in a virtual hangar, diagnosing system failures without needing access to physical components.

For technicians, the ability to train in virtual environments means they no longer have to wait for a grounded aircraft to practice troubleshooting. Instead, they can work through real-time system failures in a digital twin of a cockpit, repeating complex repairs as many times as needed before applying them in the field. Meanwhile, AR overlays are changing on-the-job training by projecting live system data onto real aircraft, guiding workers through intricate maintenance tasks step by step.

The impact of these technologies is already visible. Companies using immersive training are seeing shorter onboarding times, fewer errors, and a workforce that adapts faster to new aircraft systems. As aerospace companies race to fill skill gaps and scale training efficiently, immersive learning is shifting from an experimental tool to an operational necessity.

A new era of speed and precision in aerospace production

Bringing an aircraft from concept to reality is an intricate, high-stakes process. Every component must fit together with absolute precision, and even minor errors can cause costly delays. Yet, many aerospace manufacturers still rely on 2D blueprints, static models, and siloed workflows, making it difficult for teams to spot issues early or adapt quickly when problems arise. As demand for faster production grows, so does the need for smarter, more connected manufacturing processes—and immersive technologies are making that possible.

By AR, VR, and digital twins into production workflows, manufacturers can detect and resolve issues before they disrupt the assembly line

• Engineers no longer have to rely on paper schematics. Instead, they can step inside a virtual aircraft, interacting with a full-scale digital twin to test how components fit together before manufacturing begins. This prevents costly design flaws from making their way onto the factory floor.
• On the production line, AR overlays provide real-time visual guidance to technicians. Workers assembling complex components can see precisely where parts should be placed, ensuring accuracy while reducing rework and waste. Maintenance teams can also use AR to overlay live system data onto real aircraft, helping them diagnose issues faster.
• VR simulations allow production teams to refine workflows before making physical changes. Instead of shutting down a line to test new processes, teams can rehearse different assembly techniques in a fully simulated factory environment, identifying bottlenecks and optimizing efficiency without disrupting operations.

Some manufacturers are already adopting enterprise-scale digital twins to integrate immersive tools more effectively. For example, Capgemini’s partnership with Unity is expanding real-time 3D visualization capabilities in aerospace, allowing companies to create highly detailed, interactive models of aircraft that improve both design validation and production efficiency.

These immersive technologies are reducing errors, accelerating production, and cutting waste. Catching design flaws early prevents costly rework, while improved accuracy keeps assembly moving efficiently. With greater visibility across operations, manufacturers can scale to meet demand without compromising quality.

Customers now expect immersive buying experiences

Passenger expectations for comfort, customization, and cutting-edge design are higher than ever, and airlines and private jet operators must respond. Cabin configurations, materials, and layouts are no longer just engineering decisions—they are central to the customer experience. Yet, traditional design methods often rely on static renderings and physical mockups, making it difficult for buyers to fully grasp what their aircraft will look and feel like.

Immersive technologies are changing that. AR and VR allow buyers—whether airlines configuring new fleets or private customers designing bespoke interiors—to step inside a fully realized virtual cabin. They can walk through different seating arrangements, test lighting schemes, and see how materials look in various conditions, all before making final decisions. This level of interaction helps ensure expectations align with reality, reducing costly revisions later in production.

For aircraft manufacturers and interior designers, this shift streamlines the sales and customization process. When customers can explore their options in a virtual environment, decisions happen faster, back-and-forth revisions decrease, and confidence in the final product increases. In a competitive market where differentiation is key, offering an immersive buying experience is quickly becoming an industry standard.

Collaboration without boundaries

Aerospace production and maintenance require expertise from specialists spread across different locations, making collaboration a persistent challenge. Immersive technologies are transforming how teams work together by allowing engineers, technicians, and designers to interact in real time, no matter where they are.

For maintenance teams, AR-powered remote troubleshooting enables technicians in the field to connect with experts across the world, receiving step-by-step repair guidance without needing an on-site visit. Engineers and production teams can conduct virtual design reviews, stepping inside a shared 3D model of an aircraft to inspect components, evaluate potential issues, and refine designs before production begins. Even training programs benefit, as high-risk tasks can be practiced in controlled virtual environments, allowing workers to gain hands-on experience without real-world consequences.

By eliminating geographical barriers and enabling real-time collaboration, immersive technologies are making aerospace operations more efficient, reducing downtime, and ensuring that expertise is always within reach—no matter where a team is located.

The costs—and savings—of immersive technologies

Immersive technologies require upfront investment, but for aerospace companies, the long-term savings and efficiency gains far outweigh the costs. As hardware prices drop and digital tools improve, companies that adopt now are seeing faster training, fewer manufacturing errors, and reduced operational waste.

Costs of adoption

• Hardware & software – AR headsets, VR systems, and simulation tools require an initial investment, but costs have fallen significantly.
• Digitization efforts – Older aircraft models may lack digital twins, requiring companies to build virtual replicas before immersive tools can be fully utilized.
• Integration with legacy systems – Many aerospace companies still rely on outdated IT infrastructures, slowing large-scale adoption.

Return on investment

• Faster workforce training – Virtual training environments allow new hires to upskill quickly, reducing onboarding time and labor shortages.
• Improved manufacturing Accuracy – Real-time 3D visualization helps catch design flaws early, minimizing rework and material waste.
• Reduced downtime & travel costs – AR-assisted remote troubleshooting means technicians can receive expert guidance instantly, instead of waiting for specialists to be on-site.

Despite the challenges, immersive technologies are proving to be a cost-cutting tool rather than an expense. As adoption grows, their impact on efficiency, precision, and production timelines will only increase.

The leadership imperative

Aerospace has always been defined by innovation. From the first powered flight to the rise of commercial aviation, the industry has evolved by embracing new technologies that push the limits of what’s possible. Today, immersive technologies represent the next major shift—one that is already transforming how aircraft are designed, built, and maintained. But tools alone don’t drive change. Leadership does.

Early adopters are already seeing the impact—faster training, more precise manufacturing, and seamless collaboration across global teams. Yet, these technologies can’t be implemented in isolation. For immersive solutions to reach their full potential, aerospace leaders must take an active role in driving digital transformation. This means investing in the right digital infrastructure, fostering a culture of innovation, and aligning teams around a shared vision.

Companies that wait too long risk falling behind as competitors streamline operations and reduce costs with immersive solutions. The opportunity is here now—but the industry’s next leap forward depends on the decisions made today.

Learn more:

Digital Continuity in Aerospace

Digital Twins in Aerospace and Defense

Intelligent Supply Chain for the Aerospace and Defense Industry

TechnoVision 2024: Aerospace and Defense