Decoding the digital thread digitalization approach for product design and development: benefits, challenges, and extensions

Abstract Digital Tools are reshaping how Engineering Design data and information are produced, processed, used, reused, shared, and stored. The Digital Thread prioritizes the flow of design data and information, promoting effective collaboration and process efficiency. While literature showcases the immense application and capability of taking a Digital Thread approach to Product Design, best practices, key features, and benefits of successful implementations remain scarce. Reviewing and understanding successful implementations can assist researchers and practitioners in making informed decisions to effectively implement Digital Threads in their product design processes. This article addresses this gap by reporting a post hoc review of a collaborative Research & Development project that developed and implemented a Digital Thread approach to the design of hydrogen composite pressure vessels. A thematic analysis of the project’s reports and interviews with members of the project team was performed to identify the key features that expedite and improve the design process through an effective Digital Thread implementation. The post hoc review offers valuable insights – in the form of six feature benefits, four potential implementation challenges, three possible extensions, and four best practice recommendations – for companies looking to adopt and implement a Digital Thread approach to their design process.