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Altair Showcases AI and Smart Manufacturing at Paris Air Show 2025

Altair reveals AI-driven aerospace innovations for sustainable design, digital twins, and smart manufacturing at Paris Air Show 2025.

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Altair’s Vision for the Future of Aerospace: AI, Smart Manufacturing, and Connected Systems

The aerospace industry is undergoing a profound transformation, driven by the integration of artificial intelligence (AI), smart manufacturing, and connected technologies. At the forefront of this shift is Altair, a global leader in computational intelligence. The company is set to showcase its latest innovations at the Paris Air Show 2025, one of the world’s most prestigious aerospace events. This platform will allow Altair to demonstrate how its solutions are reshaping the aerospace sector, from conceptual design to real-time flight operations.

With aerospace organizations under increasing pressure to meet sustainability goals, reduce costs, and accelerate innovation, the role of AI and data-driven design has never been more critical. Altair’s participation at the Paris Air Show will highlight how its AI-powered engineering tools, high-performance computing (HPC), and digital twin technologies are enabling smarter, faster, and more connected aerospace development.

As part of the Siemens Digital Industries Software portfolio following a recent acquisition, Altair is positioned to deliver comprehensive digital transformation solutions. These offerings are expected to support a wide range of aerospace stakeholders, from OEMs and defense contractors to startups and SMEs, in achieving operational readiness and long-term competitiveness.

AI-Powered Engineering: Accelerating Aerospace Innovation

Revolutionizing Design with AI-Driven Simulation

Altair is pioneering the integration of AI into simulation workflows, enabling engineers to significantly reduce design cycles while optimizing structural performance. At the Paris Air Show 2025, Altair will demonstrate how machine learning algorithms are embedded into its engineering platforms to assist in decision-making, automate repetitive tasks, and improve overall design efficiency.

These tools allow engineers to explore a wider range of design variables and scenarios, ultimately leading to lighter, stronger, and more fuel-efficient aircraft structures. This is particularly relevant as the aerospace industry seeks to reduce carbon emissions and improve sustainability without compromising safety or performance.

One example is Altair’s AI-assisted modeling environment, which supports generative design and topology optimization. These capabilities empower designers to create innovative geometries that meet strict aerospace standards while minimizing material usage and weight.

“AI, data, and connectivity are no longer future concepts—they are today’s competitive advantages,” said Dr. Pietro Cervellera, Senior Vice President of Aerospace and Defense at Altair.

Digital Twins and Predictive Maintenance

Digital twin technology is another area where Altair is making significant strides. By creating virtual replicas of physical systems, engineers can monitor real-time performance, simulate stress conditions, and predict maintenance needs. This reduces unplanned downtime and extends the lifecycle of critical aerospace components.

Altair’s digital twin solutions are integrated with IoT-enabled sensors and data analytics, offering a holistic view of aircraft health and performance. These tools enable proactive maintenance strategies, improving safety and reducing operational costs. At the Paris Air Show, visitors will see how digital twins support everything from initial design validation to in-flight system monitoring.

Such capabilities are especially valuable for defense organizations and commercial airlines, where reliability and readiness are paramount. By leveraging AI-driven insights, operators can make informed decisions faster and with greater confidence.

Empowering Startups and Defense Programs

Altair is not only serving large OEMs but also supporting emerging aerospace startups and government defense agencies. Through the Altair Aerospace Startup Acceleration Program (ASAP), the company provides enterprise-grade tools to over 150 small and medium-sized enterprises (SMEs) in partnership with the Campania Aerospace District (DAC).

This initiative ensures that startups have access to the same advanced simulation and data analytics platforms used by industry leaders. It levels the playing field and accelerates innovation across the aerospace ecosystem.

Defense programs also benefit from Altair’s AI-powered platforms, which streamline development cycles and enhance mission readiness. From unmanned aerial vehicles (UAVs) to next-generation fighter jets, Altair’s solutions are enabling faster prototyping and more agile system development.

Smart Manufacturing: From Factory Floor to Flight

Real-Time Optimization for Aerospace Production

Altair’s smart manufacturing solutions are designed to meet the growing demand for precision, scalability, and efficiency in aerospace production. By integrating real-time data collection with advanced analytics, manufacturers can monitor production lines, identify bottlenecks, and optimize throughput.

This data-driven approach reduces scrap, minimizes rework, and supports continuous improvement initiatives. At the Paris Air Show, Altair will showcase how these capabilities are being applied in smart factories, enabling more adaptive and responsive manufacturing environments.

One key feature is the digital thread, which connects every stage of the product lifecycle—from design and engineering to manufacturing and maintenance. This seamless integration ensures traceability, compliance, and faster feedback loops.

Enhancing Quality and Reducing Waste

Quality control is a critical concern in aerospace manufacturing, where even minor defects can have serious consequences. Altair’s solutions use AI to detect anomalies in real-time, allowing for immediate corrective action. This not only improves product quality but also reduces material waste and energy consumption.

Predictive analytics further enhance production planning by forecasting demand, machine performance, and supply chain disruptions. These insights help manufacturers make proactive adjustments, improving overall resilience and competitiveness.

Several aerospace OEMs have already adopted Altair’s smart manufacturing tools, reporting measurable improvements in cycle times, defect rates, and operational efficiency.

Supporting Sustainability Goals

Environmental sustainability is a top priority for the aerospace industry. Altair’s technologies support this goal by enabling lighter designs, reducing energy use in production, and facilitating circular manufacturing practices.

For example, AI-assisted simulations can optimize the use of recyclable materials without compromising structural integrity. Meanwhile, digital twins help track component wear and usage, promoting refurbishment over replacement.

These innovations contribute to broader industry efforts to meet regulatory standards and reduce the environmental impact of aerospace operations.

Conclusion: A Connected, Intelligent Future for Aerospace

Altair’s presence at the Paris Air Show 2025 underscores its commitment to driving digital transformation in aerospace. By integrating AI, simulation, and connectivity, the company is enabling smarter design, agile manufacturing, and real-time system management. These capabilities are essential for meeting the evolving demands of commercial and defense aviation.

As the aerospace industry continues to embrace digital technologies, Altair’s solutions offer a blueprint for innovation. Whether through AI-powered engineering, smart factory systems, or startup empowerment programs, Altair is helping shape a more efficient, sustainable, and connected future for flight.

FAQ

What will Altair showcase at the Paris Air Show 2025?
Altair will present AI-powered engineering tools, smart manufacturing solutions, and connected aerospace systems, including digital twins and predictive maintenance technologies.

How does Altair support aerospace startups?
Through the Aerospace Startup Acceleration Program (ASAP), Altair provides SMEs with enterprise-grade tools to accelerate innovation and compete with larger OEMs.

What is the significance of Altair’s partnership with Siemens?
The acquisition by Siemens enhances Altair’s ability to deliver comprehensive digital twin and AI-powered solutions as part of the Siemens Xcelerator portfolio.

Sources: PR Newswire, Paris Air Show Official Website, Aerospace Technology Insights 2024, Aerospace Tech Conference 2024, Altair Engineering Inc. 2023 Annual Reports

Photo Credit: Altair

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Sustainable Aviation

American Airlines and Google Sign 35M-Gallon SAF Deal

American Airlines and Google agree to purchase 35 million gallons of SAF certificates, cutting nearly 300,000 metric tons of CO2e.

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American Airlines Group Inc. (AAL) and Google have signed an agreement to purchase 35 million gallons of sustainable aviation fuel certificates over the next three years, marking the largest publicly announced transaction of its kind between an Airlines and a single corporate customer.

Announced on June 9, 2026, the partnership will facilitate the delivery of physical sustainable aviation fuel (SAF) to Chicago O’Hare International Airport (ORD) via Valero Marketing and Supply Company. The agreement is projected to reduce greenhouse gas emissions by nearly 300,000 metric tons of carbon dioxide equivalent (CO2e), allowing Google to offset the environmental impact of its employee business travel.

Scaling sustainable aviation fuel

The sustainable aviation fuel certificates (SAFc) model allows corporate customers to claim the environmental benefits of the fuel even if they do not physically consume it on their specific flights. Google will utilize the SAFc Registry to apply these emissions reductions against its corporate travel footprint.

“This strategic collaboration with American Airlines demonstrates how companies can work together to scale critical sustainability technologies. By entering into this long-term commitment, we are sending a vital demand signal to catalyze investment and bring more SAF to market,” said Kate Brandt, Chief Sustainability Officer at Google.

American Airlines stated the agreement is a critical step in reducing operational emissions and growing market demand for SAF. According to the airline, the aviation industry currently accounts for 2 to 3 percent of global carbon dioxide emissions. Google noted that SAF has the potential to reduce air travel emissions by up to 80 percent compared to traditional jet fuel.

Legislative incentives and prior collaborations

The transaction was facilitated by a recently enacted sustainable aviation fuel tax credit passed by the Illinois General Assembly. The legislation is designed to incentivize the delivery and utilization of SAF within the state.

“This agreement demonstrates how our nation-leading SAF tax credit can bring industry leaders together as we work toward a more sustainable future. Through partnerships with innovators like American Airlines and Google, we’re strengthening Illinois’ role as a global aviation hub and accelerating the transition to cleaner energy,” said Illinois Governor JB Pritzker.

This SAFc agreement follows a 16-week pilot program conducted by American Airlines and Google in 2025. That initiative, which also included Flightkeys and Contrails.org, embedded contrail avoidance models into flight planning and reportedly achieved a 62 percent reduction in contrail formation.

AirPro News analysis

We view this 35-million-gallon agreement as a significant indicator of how corporate sustainability budgets are increasingly subsidizing the premium cost of SAF. While 35 million gallons over three years represents a fraction of American Airlines’ total annual fuel consumption, long-term offtake agreements are essential for producers like Valero to secure financing for expanded refining capacity. The use of the SAFc Registry also highlights the growing maturation of the book-and-claim model, which decouples the environmental attributes of SAF from the physical fuel, solving logistical bottlenecks at airports that lack the infrastructure to receive blended SAF directly.

Sources: American Airlines

Photo Credit: American Airlines

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Technology & Innovation

Vertical Aerospace Completes Valo Final Prototype First Flight

Vertical Aerospace flew its final full-scale Valo eVTOL prototype on June 5, 2026, doubling its flight test fleet ahead of a 2028 service target.

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Vertical Aerospace completed the maiden piloted flight of its final full-scale Valo electric vertical takeoff and landing (eVTOL) prototype on June 5, 2026, at the company’s United Kingdom Flight Test Centre.

Announced in a press release on June 9, 2026, the maiden flight marks the beginning of an expanded flight test campaign. The addition of this aircraft doubles the manufacturer’s flight testing capacity as it advances toward its Critical Design Review (CDR) and a targeted 2028 entry into commercial service.

Advancing toward Critical Design Review

The flight occurred at 8:49 BST under the oversight of the UK Civil Aviation Authority (CAA), with Vertical Aerospace Test Pilot Paul Stone at the controls. This aircraft is the final prototype to join the test fleet before the company finalizes its certifiable design through the CDR process. Completing the CDR will clear the path for the assembly of the first pre-production Valo aircraft.

“Getting our latest prototype into flight testing is an important milestone because it allows us to learn faster in real world conditions and keep building momentum towards certification. Expanding the flight test fleet will help us validate the aircraft more quickly, reduce risk, and move more efficiently towards bringing Valo into service,” said Stuart Simpson, CEO of Vertical Aerospace.

Hybrid-electric testing and program milestones

Following the conclusion of its all-electric flight test phases, Vertical Aerospace plans to retrofit this specific prototype to conduct hybrid-electric flight testing. The company previously announced on May 19, 2026, that it had commenced integration testing for its next-generation hybrid-electric propulsion system using a dedicated evaluation rig at Cotswold Airport.

The four-passenger Valo aircraft, which succeeds the earlier VX4 prototype design unveiled in December 2025, made its United States debut in January 2026. The manufacturer reports approximately 1,500 pre-orders for the aircraft from operators across four continents, including American Airlines, Avolon, Bristow Group, GOL, and Japan Airlines.

AirPro News analysis

We view the successful flight of this final prototype as a critical operational step for Vertical Aerospace. Doubling the active flight test fleet provides the data volume necessary to satisfy CAA certification requirements by the 2028 target. The planned transition of this airframe to hybrid-electric testing also indicates a strategic hedge, allowing the manufacturer to develop longer-range variants in parallel with its baseline all-electric model.

Sources: Vertical Aerospace Press Release, Vertical Aerospace

Photo Credit: Vertical Aerospace

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Technology & Innovation

Airbus Triples Computing Power With Two HPC6 Supercomputers

Airbus installed two Bull HPC6 supercomputers, tripling throughput to support digital testing for the A350 Freighter and future rotorcraft.

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Airbus has deployed two new high-performance supercomputers, tripling its computational throughput to accelerate the digital design and testing of next-generation Commercial-Aircraft and rotorcraft.

In a company publication released on June 9, 2026, the European aerospace Manufacturers detailed its installation of two HPC6 systems provided by Bull, a European advanced computing and artificial intelligence firm. The upgraded infrastructure allows Airbus engineers to substitute physical testing with high-fidelity digital calculations, a transition the company has been advancing for two decades.

Expanding digital testing capabilities

The integration of the HPC6 supercomputers enables Airbus to evaluate complex aircraft configurations with greater precision. The application of high-performance computing at the manufacturer has expanded beyond traditional flight physics and airframe development to include powerplant and systems testing.

Engineers can now conduct digital simulations for scenarios that previously required extensive physical trials, such as birdstrike resistance on cockpit windows and engine components.

Supercomputers help create finer 3D representations of objects, enabling the exploration of more complex design and more detailed simulations to achieve higher fidelity.

Jean Gutierrez, Scientific Computing Product Manager in Engineering at Airbus, noted that the increased capacity allows the engineering team to handle larger problems. The enhanced computing power moves the design process closer to reality by reducing the allowable margin of error, which would otherwise necessitate physical testing.

Current program support and energy management

The newly installed HPC6 systems are already operational and supporting active Airbus programs. The manufacturer confirmed the supercomputers are currently utilized in the development of the Airbus A350 Freighter, alongside future Helicopters platforms.

To mitigate the energy footprint of the expanded computing infrastructure, Airbus is developing a local heat exchange system. The initiative is designed to capture the thermal output generated by the supercomputers and redirect it into local power grids.

AirPro News analysis

We view the tripling of Airbus’ computational power as a necessary infrastructure investment to maintain pace with the industry’s shift toward model-based systems engineering. As Regulations agencies demand increasingly rigorous certification data, the ability to generate high-fidelity digital simulations for extreme edge cases provides a distinct schedule advantage. The integration of a heat recovery system also demonstrates a pragmatic approach to the high energy demands inherent in advanced computing facilities.

Sources: Airbus

Photo Credit: Airbus

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