Case Study: Technology to Modernize Aviation Maintenance
Taking XR Technology to the Flight Line
Aviation maintenance, in both defense and commercial sectors, faces challenges that impact efficiency, safety, and operational readiness. These challenges stem from:
High costs due to inefficiencies in maintenance workflows.
Increasing complexity of modern aircraft systems requiring advanced technical knowledge.
A skilled technician shortage and the need for effective knowledge retention.
Human errors in maintenance tasks.
Time-consuming documentation and training processes that slow operations.
Cramped and confined spaces that inhibit the maintainer to reference documentation while performing certain tasks
Dauntless identified Artificial Intelligence (AI), Extended Reality (XR), and wearable technology as transformative tools to address these challenges. We had the opportunity to partner with the United States Air Force to first apply immersive technologies to improve operational readiness. This case study demonstrates how XR can transform aviation maintenance - military and private sector-, provides guidelines for incorporating these emerging technologies into your business operations, and common mistakes and how to avoid them.
The Aviation Maintenance Problem: Grounded Jets, Broken Tools, and Brain Drain
During our feasibility study, we found that aviation maintenance is critical yet increasingly strained. Both commercial airlines and defense organizations face mounting challenges that threaten operational efficiency, safety, and long-term sustainability. These issues aren’t just technical, they impact the bottom line for companies and the safety and experience of passengers and personnel. Many companies feel the strain of these challenges today, and without intervention industry reports forecast that they will only worsen:
Rapid Fleet Expansion and Complexity: The aviation sector is projected to grow significantly, with global fleet sizes increasing by 4-5% annually. However, maintenance processes have not scaled at the same pace, leading to inefficiencies and operational downtime. Delays in maintenance disrupt flight schedules, costing airlines millions annually in lost revenue and compensation for passengers.
Shortage of Skilled Technicians: According to a report by Oliver Wyman, the aviation industry faces a shortfall of 12,000-18,000 maintenance workers globally, which could grow to 48,000 by 2027. This shortage increases labor costs, stretches existing teams thin, and risks compromising the quality of work.
Human Errors in Maintenance Tasks: Maintenance-related errors contribute to 15-16% of major aircraft accidents, according to data from the FAA, and aviation safety incidents are on the rise. These errors not only jeopardize passenger safety but also lead to costly investigations, reputational damage, and regulatory penalties for airlines.
Time-Consuming Documentation Processes: Inefficient document management in aviation maintenance results in technicians spending 25-40% of their time searching for information, according to a study by Comply365. This inefficiency adds to operational delays and increases the risk of non-compliance with safety regulations.
In defense, the stakes are even higher. The U.S. Air Force and other military organizations must address the urgent need for on-demand, location-agnostic training to ensure operational readiness. As personnel retire, the loss of institutional knowledge compounds the challenges of maintaining a capable workforce. Inefficient workflows and outdated documentation systems slow down critical maintenance tasks, putting mission success and national security at risk.
The Hardware Selection: Extended Reality Tools for Aviation
For these contracts Dauntless was responsible for procuring hardware. After interviewing end users across industries we developed an evaluation matrix to help customers select a headset that works for them. When maintenance shops are selecting headsets for a modernization effort, we suggest evaluating eight factors to optimize performance, safety, and user satisfaction:
Compatibility with mixed reality applications for seamless integration.
Usability in challenging environments, ensuring frontline workers can operate effectively.
Comfort and ergonomics for extended use, prioritizing user health and productivity.
Battery life to support long operational shifts without interruptions.
Safety considerations, such as pass-through or see-through capabilities, to maintain situational awareness and reduce risks in dynamic environments.
Cybersecurity to ensure compliance with enterprise or defense-grade security protocols, safeguarding sensitive data.
Computing requirements to balance processing power with lightweight, portable designs for ease of use.
Cost-effectiveness and scalability for organizations needing large-scale deployments.
All Dauntless XR software is hardware agnostic, ensuring accessibility across devices. By remaining hardware agnostic, we empower organizations to choose the tools that best fit their operational environments, budgets, and user requirements. Not all apps run on all headsets, so ensure that your chosen software is compatible with the headset you select.
For the Air Force contract, Dauntless deployed Katana XR on the HoloLens 2, a mixed reality headset chosen for its ease of use, price point, and ergonomics. Unfortunately, Microsoft ceased HoloLens2 production in 2024 and while this headset was a good choice for this pilot testing Dauntless prioritized other hardware for future deployments.
The Software Solution: How to Craft an Application for a New Era of Maintenance
After confirming technical feasibility and interviewing aircraft maintainers Dauntless compiled the follow requirements for an extended reality application to assist with aircraft maintenance:
Hardware-Agnostic Software: The end product must operate across various commercially available (COTS) headsets, ensuring flexibility and compatibility with existing infrastructure. This also protects the customer against platform lock.
Mixed Reality Interface: A mixed reality allows technicians to maintain situational awareness, while delivering digital data overlays.
Spatial Anchoring for Precision: Technicians can access step-by-step AR-guided workflows anchored to physical equipment, enabling precise and accurate maintenance tasks.
Maintenance and Training Modes: Dedicated modes for both operational maintenance and immersive training. This dual functionality allows personnel to practice tasks in a risk-free environment before applying their skills in real-world scenarios.
Digital Transformation of Paper-Based Systems: Replace outdated pen-and-paper checklists with interactive MR workflows. This transformation reduces human error, ensures compliance, and saves valuable time during critical operations.
The result of this research and development was the Katana XR platform. Katana is a cutting-edge, no-code workflow authoring tool designed to augment aviation maintenance teams with hands-free expertise. How Katana XR Works:
Transform Checklists into AR Guides: Maintenance tasks that once required lengthy documentation are now presented as intuitive, hands-free AR workflows, improving efficiency and reducing errors.
Assign and Track Tasks in Real Time: Supervisors can assign tasks directly through the platform and monitor progress, ensuring accountability and streamlined operations.
Create Instant Experts on the Job: With immersive 3D content and interactive guidance, even less experienced personnel can perform complex tasks with confidence.
Seamless Reporting and Data Collection: Katana XR automates task reporting and documentation, eliminating the paperwork burden and providing actionable insights for continuous improvement.
No-Code Workflow & XR Content Creation: Subject matter experts can use a companion web app, Katana Pro, to author and edit work flows with no coding experience. This ensures the maintainability of the content and the longevity of the usefulness of the XR content compared to hard-coded/static developed content.
Implementation and Results: Transforming Aircraft Maintenance
Defense Use Case:
Dauntless XR deployed Katana XR with the 349th Air Refueling Squadron to address knowledge capture and training challenges. The results of our final user testing included:
Enhanced training effectiveness through immersive 3D content.
Reduction in human errors during maintenance tasks.
Improved knowledge retention and 24/7 availability of training.
The positive results indicated that extended reality technology is an effective tool in modernizing aviation maintenance.
Commercial Use Case:
Given the positive results found in defense, Dauntless also explored the feasibility of implementing the same technology in commercial aviation. Based on industry research the following similar benefits are expected in business and commercial aviation:
Faster onboarding and training for new hires.
Reduction in aircraft downtime with real-time guided workflows.
Improved safety and compliance through AR-based documentation.
Lessons Learned: Bridging the Gap Between Innovation and Adoption in Aviation Maintenance
Moving to a new technology involves both a change in behavior and a change in preference. Moving to wearable represents a big shift in behavior and to successfully change behavior, we found the following best practices are required for a successful emerging technology program.
User Interface and Experience:
XR users have higher expectations for intuitive design compared to desktop or mobile platforms.
Reducing cognitive load is critical for technical users. Find the optimal balance of providing data and not overwhelming a user's field of view. We found that approximately 35 words and a single 3D model is optimal.
Users preferred mixed reality assets appear 45cm from the headset for close up interactions and at most 200cm for distance interactions.
Behavioral Adoption Challenges:
Many users have experienced negative VR experiences that induce vertigo or motion sickness.
This required us to build trust in mixed reality as a reliable tool for critical tasks.
Those unfamiliar with XR benefitted from seeing a screen share on a companion screen to understand the user experience before donning a headset.
Scalability and Integration:
Customers need a common platform to support diverse task types across aircraft. Different applications for different aircraft stifle implementation.
Hardware-agnostic solutions are essential for broader adoption.
The ability for customers to self-author and manage XR content is critical for scalability.
What’s Next for XR in Aviation Maintenance
The future of XR in aviation maintenance is promising, with potential expansions including:
Integration with digital twins for predictive maintenance.
Use of spatial audio and "see-what-I-see" video for remote assistance.
Deployment across commercial aviation fleets to standardize global maintenance processes.
Taking Maintenance to New Heights
The application of XR, exemplified by Katana XR, has proven to be a transformative solution for addressing aviation maintenance challenges. By reducing human errors, improving training, and streamlining workflows, XR technology is poised to redefine aviation maintenance standards.
