Aerospace and defense programs are confronting a perfect storm of compressed development timelines, mission complexity, sustainability mandates, and relentless cyber threats. Traditional stage-gated engineering, paper-based compliance, and siloed supply chains no longer suffice when commanders demand multi-domain advantages and lawmakers require auditable carbon footprints. Sky
Forge(tm) is VSI Technologies' answer: a single, secure environment that unites model-based systems engineering, AI-assisted design, digital thread analytics, and continuous mission support from concept through sustainment. Sky
Forge begins with authoritative digital twins that replace static drawings and email handoffs. Systems architects model requirements, behaviors, interfaces, and verification criteria in Sys
ML, while domain specialists contribute CFD meshes, composite lay-ups, and software containers. All artifacts reference a shared ontology, so a change to antenna gain instantly propagates to power budgets, thermal loads, and electromagnetic compatibility checks. Versioned data lineage delivers real-time impact analysis–a far cry from months of manual reverification. Generative engineering tools embedded in Sky
Forge explore thousands of design permutations per hour. Constrained by physics, manufacturability rules, and ITAR export classifications, AI algorithms propose lighter structures, lower-observable inlets, or battery placements that maintain center of gravity. Engineers select promising concepts, then run multiphysics simulations–fluid, thermal, vibro-acoustic–on demand across elastic GPU clusters operating in Fed
RAMP High regions or classified enclaves. Computational notebooks store every boundary condition and solver setting, satisfying DO-160, MIL-STD-810, and NATO AQAP documentation out of the box. When prototypes transition to production, Sky
Forge's digital thread links every part number to additive-manufacturing parameters, inspection CT scans, and supply-chain certificates. Blockchain-anchored pedigree records prove origin and tamper-evidence, blocking grey-market components or counterfeit fasteners from entering the build. A sustainability ledger calculates cradle-to-gate CO2 and water usage, enabling greener material choices and compliance with emerging defense-sector ESG directives. Software is treated as a first-class citizen. Dev
Sec
Ops pipelines compile avionics code, generate signed SBOMs, and push containers to real-time operating environments under deterministic scheduling. Static and dynamic scanners enforce MISRA-C, CERT-C++, and NIST SP 800-218 secure-software frameworks. Zero-trust tokens and runtime attestation ensure only authorized binaries execute on mission hardware, whether in flight, at sea, or on orbit. Cybersecurity weaves throughout Sky
Forge. e
BPF-based sensors monitor system calls on embedded Linux, streaming anomalies to VSI's Global Cyber Fusion Centers where machine-learning classifiers distinguish benign jitter from command-and-control beacons. Cryptographically sealed logs meet NSA CSf
C and UK DSTL standards, providing prosecutable evidence without disrupting performance budgets. Test and evaluation shift left. Hardware-in-the-loop rigs emulate sensors, actuators, and RF conditions so teams validate autopilot algorithms and electronic-warfare responses early. Digital mission rehearsals inject weather, adversary tactics, and satellite link degradation into the twin; commanders visualize probability of success and fuel margins long before field trials. Once prototypes roll onto the range, telemetry flows back into Sky
Forge for immediate model refinement. Sustainment closes the loop. Deployed platforms stream health indicators through encrypted SATCOM or private 5G links. Predictive analytics forecast bearing failures, corrosion hotspots, and battery fade, allowing maintainers to schedule repairs during planned downtime instead of mission-killing surprises. Interactive 3-D manuals generated from design twins guide technicians with AR overlays, cutting mean time to repair and reducing training hours for new personnel. Compliance burden melts away. Sky
Forge auto-populates artifacts required for Airworthiness Directives, FAA Part 21 submissions, STANAG certifications, and NASA 7120.5 reviews. An auditor can trace every requirement to test evidence and signed commit in minutes. Configuration-control workflows enforce segregation of duties; change boards approve deltas through secure multilevel portals; and digital signatures provide non-repudiation. The platform is extensible. Partners integrate radar cross-section solvers, composite ply simulators, or advanced space-radiation models via APIs. Sovereign-cloud options host classified workloads within national borders, with encryption keys managed by defense customers. For coalition programs, attribute-based access controls enable data sharing at releasable granularity, unlocking joint innovation without risking sensitive information. Business outcomes are compelling. A hypersonic-missile program shaved eighteen months off its critical design review and avoided a $200 million cost overrun. An unmanned aerial-system startup certified DO-178C Level-A software with 60 percent fewer test cases thanks to coverage analytics. A naval shipyard cut parts procurement time by 40 percent and saved 4,000 metric tons of CO2 annually through additive manufacturing and energy-aware routing. Sky
Forge engagements follow a crawl-walk-run model. A 90-day Pathfinder connects existing PLM, PL/I, and telemetry feeds, proving digital-thread visibility on a single subsystem. A Phase-Two rollout scales across programs of record, instituting model governance and AI-driven design loops. Phase Three evolves into a strategic partnership: VSI seats reliability analysts, data-science fellows, and test-range integrators inside customer command centers, sharing KPIs and incentives. Commercial structures flex with mission needs. Subscription tiers cover core platform, simulation credits, and over-the-air updates. Outcome-based contracts tie VSI's margin to schedule adherence, readiness rates, and carbon-intensity reductions. For startups, a pay-as-you-grow plan matches costs to funding milestones, de-risking adoption. In an era where air superiority can hinge on software readiness and logistics resilience, Sky
Forge delivers integrated digital engineering that keeps pace with adversary advances, regulatory scrutiny, and planetary stewardship. It empowers aerospace and defense innovators to imagine boldly, engineer rapidly, and sustain affordably–turning strategic vision into operational advantage.
