Can digital twins rescue the Pentagon’s most expensive program?
Congress is limiting the number of F-35 jets the U.S. military can accept until detailed digital models are fully developed and implemented. The restriction is part of the 2025 National Defense Authorization Act (NDAA), which is awaiting President Biden’s signature to become law.
The Air Force Research Laboratory is opening a new facility to leverage cutting-edge digital technologies to improve the beleaguered F-35 jet program. The F-35 Joint Program Office (JPO) and its partners have invested around $70 million for the new Micro-Electronics Digital Engineering Infrastructure facility.
In addition, the House Armed Services Committee has recommended reallocating funds earmarked for F-35 jets to support digital twin development and related infrastructure. The committee proposes redirecting about $1 billion, originally intended for 10 F-35 jets, to establish an integrated software laboratory.
The state-of-the-art facility, located on the Wright-Patterson Air Force Base in Ohio, will leverage virtual models that mirror real F-35 systems in remarkable detail. Engineers will use the digital twins to test upgrades before applying them to real jets, simulate scenarios virtually to solve problems faster, and predict issues that might occur during production or in the field.
Congress limited production of F-35s in response to ongoing delays and performance issues with the F-35’s Technology Refresh 3 (TR-3) upgrades. President-elect Trump and Elon Musk have criticized the F-35 program. Musk has called the program “obsolete,” arguing jets are outdated in the era of autonomous drones. Trump has called the program’s costs “out of control” and suggested that billions could be saved.
According to National Defense Magazine, the digital twinning facility will also support other defense initiatives, including Navy projects, DARPA research, and the DoD’s Microelectronics Commons program.
Until Congress’s digital twin requirements are met, the military can only accept 30 F-35A jets for the Air Force, nine F-35B jets for the Marine Corps., and nine F-35C jets for the Navy. Lockheed Martin, the program’s prime contractor, remains central to the F-35’s design, production, and ongoing improvements.