Wing profile required multiple wind‑tunnel tests, extending development by 6 months.

Implemented CFD‑driven optimization, reducing physical testing cycles by 40% and cutting time‑to‑market by 2 months.

Structural weight margins were overly conservative, adding 5% extra mass.

Applied advanced FEA techniques to refine load paths, achieving a 5% weight reduction without compromising safety.

Design iterations were manually documented, leading to version‑control errors.

Adopted a PLM system with automated change tracking, eliminating documentation errors and saving 15 hours per project.

Fuel consumption forecasts were based on legacy models with 8% error.

Integrated real‑time simulation tools, improving fuel burn predictions to within 2% of actual performance.

Component layout caused cable routing conflicts, requiring redesign.

Used 3‑D layout software to detect clashes early, preventing costly rework and saving $200k.