_Optimizing the cost and time of defense product certification with PLM

The modern defense industry faces numerous challenges, including rising costs and increasingly complex certification processes. Obtaining certification for defense products requires compliance with strict safety standards, conformity testing, and precise documentation—factors that can lead to delays and additional expenses. 

In response to these challenges, organizations are increasingly turning to advanced Product Lifecycle Management (PLM) solutions, such as those offered by PTC. With PLM, companies can accelerate the certification process while reducing its cost, which translates into greater competitiveness and operational efficiency. 

Challenges in defense product certification 

Certification of defense products is a complex process that includes multiple stages such as design, testing, audits, and meeting stringent regulatory requirements. Any error, delay, or documentation inconsistency can result in additional costs and the risk of product rejection by decision-making institutions. 

Key challenges in the certification process: 

• Regulatory complexity – Defense products must meet the requirements of many national and international institutions such as NATO, EASA, or the U.S. DoD. 
• Lengthy process – Certification can take from several months to several years, affecting the timelines for implementing new technologies. 
• High testing and compliance costs – Testing requires advanced laboratories and procedures, generating significant expenses. 
• Data and documentation management – Maintaining up-to-date and consistent documents is crucial to avoid redundant work and administrative errors. 

The role of PLM systems in optimizing certification 

Product Lifecycle Management systems like PTC Windchill play a key role in streamlining the defense product certification process. The right PLM software centralizes data, automates processes, and improves control over product compliance with regulatory standards. 

Modern engineering practices in defense systems

Defense organizations are accelerating innovation by leveraging configuration management and model based systems engineering (MBSE). These approaches ensure tight control over design changes and enable teams to work collaboratively using digital models, reducing errors and speeding up certification. The digital thread connects data across the product lifecycle, ensuring full traceability and supporting regulatory compliance. With these digital practices, defense systems are certified faster and adapt more rapidly to evolving requirements.

Benefits of implementing PLM in the certification process: 

• Reduced operational costs – Automated documentation management minimizes the need for manual data processing and reduces the risk of errors. 
• Faster certification – A central system for managing requirements and documentation eliminates the need for repeated approvals of the same information. 
• Improved team collaboration – PLM provides a unified platform for engineering, quality, and legal teams, reducing decision-making delays. 
• Better requirement control – Tools for tracking changes and auditing compliance enable quick responses to new regulatory demands. 

How PTC Windchill supports defense product certification optimization 

• Automated management of documentation and requirements
  Windchill enables collection, processing, and updating of certification documentation in one system, eliminating the risk of discrepancies and duplicated efforts. Process automation allows faster report and certificate generation. 
• Digital verification and validation
  Through digital twins and computer simulations, companies can test products in a virtual environment before conducting costly physical tests. This reduces the number of iterations and shortens the time required to achieve compliance. 
• Integration with CAD and ERP tools
  Windchill fully integrates with CAD and ERP systems, synchronizing design and operational data in real time. Engineering and production teams gain access to consistent information, minimizing design errors and delays. 
• Change tracking and auditing
  PTC’s PLM system enables precise tracking of requirement and specification changes. Companies can easily generate compliance reports, expediting audits and approvals. 
• Security and access control
  PTC solutions ensure high security standards, allowing controlled access to data and compliance with classified information protection regulations. This is a critical aspect in the defense industry, where document control is a top priority. 

PLM in the aerospace industry

A prime example of successful PLM implementation is the digital transformation of Airbus Helicopters GmbH. The company migrated data from a traditional Product Lifecycle Management system to modern Windchill software from PTC. This enabled centralized documentation, improved product lifecycle management, and optimized certification processes. The new system helped Airbus Helicopters boost operational efficiency, shorten document approval times, and minimize risks associated with outdated or incomplete data.

Read more here: Data Migration from a Traditional PLM System to Windchill PLM Software as the Beginning of Digital Transformation at Airbus Helicopters GmbH

PLM in the defense sector – challenges

Despite numerous benefits, implementing PLM systems in defense organizations presents several challenges:

• Integration with existing IT infrastructure – Companies often have legacy data management systems that require complex migration to modern PLM platforms.
• High security requirements – The defense industry operates in an environment where access control and protection of classified data are critical.
• Implementation costs and time – Deploying a PLM system requires financial investment and resources, and full utilization may take several years.
• Employee training – Transitioning to modern solutions requires well-prepared teams, which can temporarily reduce productivity.

Comparing PLM with traditional certification management methods

In traditional approaches, documentation management relies on manual processes, increasing the risk of errors and complicating data updates. Implementing a PLM system like Windchill eliminates these issues through automation and centralized information. Traditional certification is time-consuming, as it requires multiple document approvals. In PLM, the entire process is accelerated through data integration and automated workflows.

In terms of operational costs, traditional methods incur high expenses due to manual document handling, while integrating PLM reduces these expenses by eliminating unnecessary administrative tasks. Moreover, traditional change tracking in documentation is limited, leading to inconsistencies and redundant work. PLM systems provide full control over changes and enable rapid compliance audits.

The future of certification in the aerospace and defense industry

In the coming years, certification processes in defense companies will increasingly rely on modern technologies. Key trends include:

• Artificial Intelligence and Machine Learning – AI can automate document analysis and support regulatory compliance.
• Blockchain for documentation management – Blockchain can ensure transparency and immutability of certification documents.
• Digital twins – Virtual product models will enable more accurate testing and simulations before physical trials.
• Dynamic regulations – With growing geopolitical tensions and changing laws, systems must adapt to new regulatory requirements.

The impact of regulations and geopolitical changes on PLM development

The global defense industry is continuously subject to regulatory changes. New EU, U.S., and international regulations affect certification requirements. Additionally, increasing geopolitical uncertainty means companies must quickly adapt to evolving standards and export requirements. PLM systems enable dynamic change management and rapid adaptation to new regulations, offering a significant competitive advantage.

With these solutions, defense sector companies can not only optimize certification processes but also better respond to future challenges.

Key regulatory frameworks:

• ITAR (International Traffic in Arms Regulations) – U.S. export regulations for military technology requiring strict control of product data access.
• MIL-STD (Military Standards) – Technical and quality requirements for military equipment.
• AS9100 – Quality management standard for the aerospace and defense industry, regulating production and component verification.
• EU Regulations – Including Council Regulation (EC) No. 428/2009 on dual-use export controls and Directive 2009/43/EC simplifying intra-EU defense product transfers.
• NATO AQAP (Allied Quality Assurance Publications) – Quality standards ensuring process compliance among NATO allies.
• International export control regimes – Such as the Wassenaar Arrangement, Missile Technology Control Regime (MTCR), and Australia Group, which restrict trade in specific military and dual-use technologies.

Adapting PLM systems to these standards ensures full audit compliance and enables secure data exchange between suppliers, clients, and government agencies. When implementing PLM, companies must account for information confidentiality management and ensure document storage and archiving meets the highest security standards.

The role of AI and data analytics in defense or aerospace PLM

Technological advances in Artificial Intelligence (AI) and data analytics significantly influence PLM system development. In the military sector, AI helps with:

• Predictive maintenance and fleet management – Algorithms analyze historical failure and usage data to predict breakdowns and optimize maintenance schedules.
• Automatic classification and verification of documentation – AI systems analyze large volumes of technical documents to detect inconsistencies and potential design errors.
• Supply chain optimization – Advanced algorithms monitor deliveries, detect component shortage risks, and suggest alternative suppliers.

Integrating AI into PLM contributes to reduced operational costs, increased design process efficiency, and improved compliance with military standards.

Learn more:

• PLM in the defense industry – strategic tips for CTO
• How to Measure Return on Investment (ROI) in PLM for the Defense Sector?