The role of digital twin technology in enhancing sustainable aviation transition: A state-of-the-art review and future direction

The aviation industry faces mounting pressure to align with international decarbonization goals, yet its digital sustainability efforts remain fragmented and narrowly focused. Digital twin (DT) technology has emerged as a critical enabler of real-time system modeling, predictive analysis, and operational optimization; however, its application in aviation has predominantly focused on isolated domains, such as maintenance and component design. This state-of-the-art review critically examines the current landscape of DT adoption across aviation, highlighting its traditional roles and identifying key limitations in addressing holistic sustainability objectives. Drawing insights from advanced implementations in adjacent sectors, including energy, automotive, maritime, and smart cities, the review proposes a comprehensive, multi-domain digital twin framework for sustainable aviation. The framework encompasses six interrelated domains: fuel and propulsion systems, lifecycle sustainability assessment (LCSA), certification support, sustainable airframe design, operational optimization, and end-of-life management. Through this integrated lens, DTs are positioned not merely as tools for performance enhancement but as strategic infrastructures capable of embedding environmental intelligence across the aviation lifecycle. This work synthesizes academic advances and industrial progress between 2010 and 2025, providing a critical foundation for future digital transformation initiatives in aviation. It advocates for the development of interoperable, lifecycle-aware DT architectures to accelerate the sector’s transition toward net-zero emissions and sustainable value creation. • A holistic Digital Twin (DT) framework enables system-level sustainability integration across the aviation lifecycle. • Cross-sectoral insights demonstrate how DTs can unlock underexploited environmental value beyond performance gains. • DT-driven lifecycle sustainability assessment (LCSA) allows real-time emissions tracking and material impact evaluation. • Integration of DTs into certification processes helps bridge the gap between emerging technologies and regulatory standards. • Application of DTs in end-of-life management enhances traceability, recycling efficiency, and circularity in aviation systems