The new dimension of defense: Why speed matters over security

### Faster than the enemy: Why the Bundeswehr must now put everything on the line ### The secret weapon of the future? What the "digital thread" means for our security ### Software instead of steel: The radical change that will decide the wars of the future ###

The Warfare Revolution: How a Digital Nervous System Is Transforming Defense

The global security landscape has changed dramatically in recent years. After decades of relative stability and a focus on asymmetric conflicts, Western nations are once again confronted with the possibility of interstate clashes. Technological superiority, long taken for granted, is increasingly being challenged. In this new paradigm, one factor is more crucial than ever: speed. It's no longer just about the speed of tanks or aircraft, but about the speed of the entire defense industry value chain. From the initial idea for a new weapon system through its development, production, and maintenance to rapid adaptation to new threats in the field – every second counts.

The defense industry, traditionally characterized by long development cycles, bureaucratic hurdles, and fragmented processes, is under enormous pressure to adapt. Conflicts today are developing at a rapid pace, driven by digital technologies and the rapid flow of information. An adversary can develop a new drone tactic overnight, deploy a new cyber weapon, or modify a known system in an unexpected way. The ability to not only react to such developments, but ideally to anticipate them, has become a central criterion for the operational capability of modern armed forces.

But the reality is often different. Outdated structures, endless decision-making processes, and a culture that prioritizes risk aversion over agility are hampering the necessary momentum. However, policymakers recognize the strategic importance of digital transformation. Significant investments, such as the €300 million provided by the Deep Tech Defense Innovation Fund (DTDIF), are being specifically channeled into the development of digital defense technologies. The message is unmistakable: Those who fail to embrace digitalization not only lose their competitiveness but ultimately endanger national security. In this context, speed is no longer a viable option; it is the absolute prerequisite for maintaining defense capability.

However, this unavoidable change brings with it profound challenges. It's not about digitizing individual processes, but about rethinking the entire organization. The transformation touches on five key, intertwined problem areas: outdated systems, complex regulations, reactive maintenance strategies, pervasive cyber threats, and the need for comprehensive interoperability. The solution to these challenges lies in a holistic approach that not only accelerates processes through digitalization but also creates a higher level of security and resilience.

The Digital Thread as a Nervous System of Modern Defense

At the heart of the solution to these complex challenges lies a concept known as the "Digital Thread." It can be thought of as the digital nervous system of a defense project. It is a consistent, integrated data structure that connects all information about a system throughout its entire lifecycle – from initial requirements and design through simulation, testing, production, and operations to maintenance and eventual decommissioning.

In the past, this information was stored in isolated silos. Engineers worked in their CAD and PLM systems, manufacturing in their MES and ERP systems, and maintenance teams used separate logistics and maintenance software. Data exchange between these departments was often manual, error-prone, and slow. The Digital Thread breaks through these silos. It creates a single, authoritative source of truth that all stakeholders can access in real time. A change to a component's design by an engineer is immediately visible for production planning, quality assurance, and the creation of technical documentation.

This seamless data availability is the foundation for addressing the industry's core problems. It not only enables radical acceleration of processes but also creates unprecedented transparency and traceability, which is essential for security and compliance.

Legacy system vulnerability: The transition to software-defined defense

A recurring problem in the defense world is scenarios based on outdated systems and processes. An aircraft carrier stuck in port for days due to a trivial software bug, or an advanced weapon system that can't be updated against a new threat because the relevant documentation is untraceable or outdated – these aren't fictional stories, but real incidents that directly threaten operational readiness. The root cause often lies in a hardware-centric mindset.

In the past, security-critical functions were embedded deep in a system's hardware or firmware. Upgrading typically involved expensive and time-consuming physical intervention: replacing circuit boards, retrofitting entire modules, or even replacing the entire system. This approach is no longer viable in today's rapidly evolving threat landscape. The future belongs to software-defined defense (SDD).

In SDD systems, critical capabilities – such as radar detection algorithms, radio system encryption, or the control logic of a defense missile – are implemented in software. This allows the systems to continuously adapt to new threat situations without having to make physical modifications to the hardware. Is an enemy jammer using a new frequency? A software update can instruct your own communications system to avoid that frequency. Is a new generation of stealth drones emerging? An update to the signal processing algorithm can improve the radar system's ability to detect them.

However, this agility is only possible if the software distribution process is absolutely secure, reliable, and traceable. This is where the digital thread plays a crucial role. It ensures that the exact hardware revision and software version installed on every single system in the field is known. It manages configurations and dependencies and enables the automated, secure rollout of updates. Tamper-proof versioning and seamless traceability ensure that only authorized and tested software reaches the systems. This drastically reduces downtime, as updates can be deployed remotely and often even during ongoing operations, and increases resilience against unforeseeable attacks.

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The regulatory jungle: Compliance through a consistent data strategy

The defense industry is one of the most tightly regulated sectors in the world. Companies must comply with a multitude of international standards and norms that affect every aspect of their work. These include, for example, ISO 15288 for systems engineering, which defines the entire lifecycle process of systems; ISO 27001 for information security management, which is becoming increasingly important in a digitalized world; and DIN EN 9100, a specific standard for quality management in aerospace and defense.

These requirements extend across all departments and phases of a project – from initial requirements analysis to decommissioning. Traditionally, demonstrating compliance with these standards is an immense undertaking. It requires the manual creation and maintenance of thousands of documents, reports, and evidence. Audits require laboriously compiling information from various departments and systems, which is not only time-consuming but also error-prone. The risk of violating a regulatory requirement is high and can have serious consequences, from financial penalties to loss of contracts.

A consistent digital thread transforms this process from a burden to an integral part of the workflow. It ensures that all relevant data throughout the product lifecycle is documented automatically, tamper-proof, and contextually. Every design decision, every test result, every material batch, and every maintenance performed is digitally recorded and linked to the original requirement.

This represents a revolution in the way companies handle compliance. Audits and certifications can be completed much faster, as all required documentation is available at the touch of a button. Regulatory risks are minimized because compliance with processes is systematically ensured and not left to chance. Furthermore, the Digital Thread creates unprecedented transparency in supply chains and procurement programs, which is particularly crucial for complex, multinational projects.

From reaction to anticipation: The revolution of forward-looking maintenance

An undetected hairline crack in a turbine blade, a slowly degrading sensor in a target acquisition system – often it's seemingly minor details that can have catastrophic consequences. Unexpected system failures in the defense sector not only cause immense costs, but in an emergency, they can mean the difference between mission success and failure, and even life and death. For a long time, the traditional maintenance strategy was reactive ("repair after failure") or preventative at rigid intervals (e.g., replacing a part after 1,000 hours of operation, regardless of its actual condition).

These approaches are inefficient and unsafe. A data-driven maintenance strategy, enabled by the Digital Thread, transforms these reactive processes into forward-looking maintenance. Modern defense systems are equipped with a multitude of sensors that continuously collect data about their condition: temperatures, vibrations, pressure, material fatigue, and much more.

This real-time data from the networked systems flows back into the digital thread and is compared with the system's digital twin. The digital twin is a highly precise virtual replica of the physical product that simulates not only its geometry but also its behavior under real-world conditions. By comparing the real sensor data with the simulation models and using artificial intelligence, algorithms can detect minimal deviations from the normal state and predict the future failure of a component with a high degree of probability.

Instead of waiting for a failure to occur, companies can now act proactively. They can plan maintenance cycles much more efficiently and replace only those parts that are actually showing wear. Costs are drastically reduced through early fault detection and the avoidance of expensive consequential damage. Most importantly, the usability and availability of systems are massively improved, and downtime is significantly reduced. The earlier a potential problem is detected, the faster action can be taken. In an emergency, it is precisely this ability to prevent a failure before it occurs that is crucial for superiority.

Cyber security: Protection in a fully connected defense landscape

Modern defense systems are no longer isolated islands, but highly interconnected digital ecosystems. A battle tank communicates with reconnaissance drones, a warship receives targeting data from satellites, and a soldier in the field accesses tactical information via their tablet. This interconnectedness is a tremendous advantage, but at the same time creates a massive attack surface for cyber threats. The demands on cybersecurity have increased exponentially as a result.

Security can no longer be viewed as an added feature after the fact. It must be an integral part of the development, production, and maintenance process from the outset and throughout the entire lifecycle. This is often referred to as "security by design" or, in the context of software development, the DevSecOps approach. An attacker can attempt to steal intellectual property during the development phase, introduce malware into the supply chain via a compromised supplier, or cripple systems in use through hacking, disruption, or tampering.

A digital thread with embedded cybersecurity ensures that security aspects are considered at every stage. It enables the secure management of identities and access rights, ensuring that only authorized individuals can access sensitive data. It ensures that security-critical software updates are distributed via a protected and traceable channel. Centralized and tamper-proof data management makes it significantly more difficult for attackers to undetectedly modify data or inject malicious code.

By continuously monitoring data flows in the digital thread, companies can identify cyber risks early and ensure seamless compliance with security standards. The ability to prevent tampering and ensure data integrity from initial design to final use is of vital importance at a time when the next war may begin in cyberspace.

Interoperability: The art of collaboration in the global ecosystem

In modern defense, hardly any nation acts alone. Operations usually take place within alliances like NATO, where armed forces from different countries must work together seamlessly. A German Eurofighter must be able to be refueled by an Italian tanker aircraft, a French soldier must be able to receive targeting data from an American drone, and a multinational staff must have a common situational awareness. This ability to work together is called interoperability and is a crucial key to success.

Interoperability has several levels. Technical interoperability ensures that systems can communicate with each other physically and data-wise, which requires the use of common standards. Process interoperability aims at optimized and coordinated processes between different companies or military units. And organizational interoperability enables efficient collaboration between international partners at the strategic level.

In practice, achieving interoperability is a huge challenge. Different manufacturers use different systems, data formats, and processes. Data exchange between partners is often characterized by media disruptions – data is manually transferred from one system to another, which is slow and error-prone. A digital thread addresses this problem at its core by creating a uniform, standardized data structure. It eliminates media disruptions and ensures a seamless, secure, and controlled exchange of information. It acts as a common language that enables the systems and organizations of different partners to communicate effectively with each other. This not only accelerates multinational development and procurement projects, but is also a fundamental prerequisite for an effective, integrated force in operations.

Future-proof defense through strategic digitalization

The speed of innovation and adaptation today determines the success and deterrent effect of defense companies and armed forces. The key prerequisite for this is a consistent digital thread strategy that embeds all processes, data, and partners into a unified, integrated digital structure. Companies that pursue this holistic approach not only increase their agility and flexibility, but also ensure strict compliance with regulatory requirements and sustainably improve their performance.

The path to digital transformation is not a sprint, but a strategic marathon. It requires more than the implementation of isolated software solutions. It demands a gradual but consistent expansion of digital processes based on a clear vision and a structured methodology. It involves systematically identifying digital bottlenecks and making data-driven decisions for process optimization.

The challenges facing the industry are specific and complex. Partners with extensive experience in the global defense and aerospace industries can help companies leverage proven frameworks to optimize digital processes and significantly accelerate innovation cycles. The question facing every company in the defense industry today is no longer whether, but how quickly, they can implement digital transformation. Which processes need to be prioritized to achieve the greatest speed advantage? How agile is the organization truly when it comes to responding to new threats? Jointly answering these questions and consistently implementing a data-driven strategy is the only way to ensure future-proof defense and guarantee security in a rapidly changing world.

Markus Becker

I would be happy to serve as your personal advisor.

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Chairman SME Connect Defense Working Group

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Konrad Wolfenstein

I would be happy to serve as your personal advisor.

contact me under Wolfenstein ∂ Xpert.digital

call me under +49 89 674 804 (Munich)

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