Digital twins for next-gen submarine construction
- May 7, 2025
- William Payne

Defence AI specialist BigBear.ai is to deploy its AI/ML-powered heavy manufacturing planning and production platform for Austal USA. Based in Mobile, Alabama, Austal USA is one of the largest shipbuilders in the United States, and a module supplier for US Navy submarines.
Supporting a major manufacturing modernisation programme, Austal USA will employ BigBear.ai’s shipbuilding software platform, Shipyard AI, including digital twins, to streamline its shipbuilding capacity planning. This aims to maximise efficiency and cost savings for Austal USA and the US federal government.
US shipbuilders are facing resource and capacity constraints. These can create costly bottlenecks. A limited labour force compounds challenges facing the country’s shipbuilders.
BigBear.ai’s Shipyard AI will support Austal USA in capacity planning in optimising use of shipyard real estate and resources. As a result, BigBear.ai will help ensure the US sustains a strong deterrent posture and retains the capability to rapidly project force against perceived adversaries.
“We are honoured to support Austal USA in its mission to modernise and scale naval submarine production in the United States, ultimately serving important national defence efforts,” said Kevin McAleenan, chief executive of BigBear.ai. “Our Shipyard AI platform was developed by, and for, shipyard planners and builders to provide heightened efficiency and efficacy at each stage of the shipbuilding life cycle, minimising costly delays in production and ultimately delivering vessels to their mission operators more quickly.”