Simulation-Based Route Analysis and Digital Twin Integration for Electric Aircraft and eVTOL Design & Operations

The rapid expansion of electric aviation and eVTOL operations introduces tightly coupled challenges related to energy‑constrained aircraft design, battery and thermal management, mission planning, and the generation of certification‑relevant evidence. This paper presents an integrated simulation workflow developed by AVL, Unisphere, and blueflite that combines high‑fidelity electric powertrain and battery models with a guidance‑level, digital‑twin‑based 4‑D trajectory simulation driven by historical weather and operational constraints. At each mission time step, the trajectory layer provides time‑resolved environmental and routing conditions, while the system‑level models compute instantaneous power demand, state‑of‑charge evolution, and thermal response, enabling mission feasibility assessment under realistic wind, temperature, and airspace effects. The workflow is calibrated and validated using flight telemetry from blueflite's active eVTOL cargo aircraft development, ensuring alignment between simulation assumptions and real‑world mission execution. The validated framework is subsequently applied to seasonal route studies and large‑scale virtual flight campaigns spanning multiple regions and years, enabling statistically robust assessment of energy margins, thermal behavior, and mission‑duration variability. The results demonstrate how integrated, traceable simulation can bridge conceptual design and real‑world electric flight operations, supporting informed decision‑making by OEMs and operators in aircraft design, validation, and deployment planning.