Quantifying Return on Investment in Digital Technical Data Packages for Combat Systems: A Life Cycle Perspective

Abstract

Combat system acquisition is shifting toward digital engineering (DE) as a strategic necessity for accelerating warfighting capability. Traditional Technical Data Package (TDP) development relies on physical integration and live testing, often causing delays and high costs. Digital TDPs instead enable virtual performance exploration, executable mission threads, and early configuration control. Even in sustainment phases, they support faster updates and reduce risk through model-based validation. Using ACAT I benchmarks, this paper quantifies DE return on investment (ROI) across the life cycle. One case draws on early Model-Based Test and Evaluation (MBT&E) applied to the AEGIS Ballistic Missile Defense baseline, reducing live-fire tests by 50%, avoiding about $222 million in costs, and producing a reusable modeling and simulation environment. A second case examines the Threat Digital Twin Advanced Technology Demonstration, showing how validated digital twins improve design performance, reduce test burden, and enable reuse across variants. Results show DE delivers ROI at any life cycle stage, with the largest gains in Operations and Support, where most life cycle costs occur. Key benefits include fewer live tests, faster integration and validation, improved configuration management, and greater stakeholder confidence. DE transforms acquisition into a faster, more resilient force multiplier.