Exploring AR to Improve Maintenance Operations
Pilatus Aircraft Ltd, known for its high-performance aircraft, wanted to explore augmented reality to improve maintenance operations as part of an innovation initiative. Partnering with us, they created an AR pilot project that provides engineers with immediate access to real-time instructions and documentation, speeding up the maintenance process and reducing aircraft on ground (AOG) time.
With over 300 talented engineers designing robust and reliable private jets and highly skilled mechanics, Pilatus leads the market in crafting versatile, high-performance aircraft with outstanding short-field capabilities and smooth handling.
The key to Pilatus’ reliability lies in high quality maintenance work, guaranteed at service centers around the globe. Looking to further enhance this, the team at Pilatus explored augmented reality to innovate with an experimental setup for maintenance facilities, providing engineers with detailed, convenient instructions for repairs and upkeep.
Scope of Work
A careful ideation and mapping of use cases should be at the core of a flexible but repeatable process that decreases risk for enterprise innovation departments who want to explore AR/VR in their operations.
Strategy & Consultation
We collaborated with Pilatus Aircraft Ltd to understand their unique use cases, conducting in-depth research to make sure the solution addressed real-world engineering challenges.
AR Prototype Application Development
We developed an augmented reality test application that delivered immersive, step-by-step maintenance instructions, helping engineers efficiently perform maintenance work.
Device Compatibility & Testing
We built and optimized the application for Magic Leap 2 and Apple Vision Pro. The application for Magic Leap 2 was developed in Unity, providing future flexibility and adaptability across new and existing hardware platforms.
Field Testing & Iteration
We conducted on-site testing with engineers to gather feedback and iterated the trial solution to fit the in-the-field needs of engineers in small spaces and challenging environments.
Choosing the right partner for a feasibility study
Innovation projects hold inherent risk — companies know they have to pursue them to stay ahead of the competition but there’s always the risk of picking the wrong technology, the hype dying out, or working with the wrong partner who will delay getting the desired outcome.
Hiring an external partner who advises and helps develop the solution significantly reduces the time of project completion, especially when the partner has completed multiple similar projects.
- No need to reinvent the wheel when someone has already been in the trenches, did the research and developed many AR/VR products.
- No hiring overhead and long-term contracts.
- Building an internal knowledge base for further innovations and use cases.
- Making more informed business decisions as to the direction of innovation projects with lower costs and risk.
Scope of Work
A careful ideation and mapping of use cases should be at the core of a flexible but repeatable process that decreases risk for enterprise innovation departments who want to explore AR/VR in their operations.
Strategy & Consultation
We collaborated with Pilatus Aircraft Ltd to understand their unique use cases, conducting in-depth research to make sure the solution addressed real-world engineering challenges.
AR Prototype Application Development
We developed an augmented reality test application that delivered immersive, step-by-step maintenance instructions, helping engineers efficiently perform maintenance work.
Device Compatibility & Testing
We built and optimized the application for Magic Leap 2 and Apple Vision Pro. The application for Magic Leap 2 was developed in Unity, providing future flexibility and adaptability across new and existing hardware platforms.
Field Testing & Iteration
We conducted on-site testing with engineers to gather feedback and iterated the trial solution to fit the in-the-field needs of engineers in small spaces and challenging environments.
Solution — Experimental Setup for Maintenance Work
#1. Initial proof of concept (POC)
The project originated in Pilatus innovation department — initiative was driven by the need for a device-agnostic solution adaptable to various hardware platforms.
Our team at Nomtek initially developed a small POC for the Apple Vision Pro. The pilot project demonstrated the device’s powerful graphics, perfect for use in business showcasing and sales presentations. It also revealed a huge potential augmented reality holds for the aviation industry.
Pilatus now wanted a more comprehensive, device-agnostic prototype that could be adapted to new headsets, making sure the company always used industry-leading hardware.
#2. Development of Magic Leap 2 prototype application
Following Pilatus’ need for a more adaptable solution, we chose Magic Leap 2 because of its strengths in holographic rendering, see-through lenses, and hands-free control, including voice recognition — features that made it more suitable for engineers working in the field.
Field testing
After developing the Magic Leap 2 app prototype, our team conducted on-site field testing at Pilatus. We visited the client’s engineering sites to test both devices with a representative group of users, including engineers and mechanics. The goal was to gather real-world feedback on how the apps performed in practical settings and understand user needs in more depth.
The testing phase highlighted the following insights:
- Magic Leap 2 was preferred for fieldwork due to its lightweight design, see-through capability, and comfort, making it more practical for long-term use in servicing centers.
- Apple Vision Pro was effective in business presentations and training, but had limitations in pass-through lag and material durability for field work.
#3. Balancing innovation with practicality
The team at Pilatus understands the immense potential of augmented reality in aviation, with applications ranging from remote assistance and pilot training to product presentations and onboarding. Yet, the true success of these solutions depends on the careful alignment of use cases with hardware capabilities to balance innovation with practicality and business strategy.
Every innovation should fill the customers with a certainty that they fly in the best aircraft, built and serviced using the best skilled maintenance people with the spot-on technology.
Team Composition
Building an innovation case called for a combined experience of developers and designers who worked closely with the engineers at Pilatus to deliver the best field experience.
Project Manager
QA Engineer
3D Developer
3D Designer
UX/UI Designer
.png)
%201.png)
