StratoShield

What it does

Smart Emergency Survival Pods use AI and Digital Twin technology to predict aircraft failures and autonomously deploy fireproof survival pods before impact, greatly improving passenger safety and survival during catastrophic air disasters.

Your inspiration

The idea was inspired by the tragic Air India Flight 171 crash in June 2025, which claimed 241 lives. Alongside this, recent crashes involving fighter jets and private aircrafts in India and globally reflect a growing safety concern in aviation. While pursuing my Master’s in Engineering Business Management, I learned how Digital Twin technology can be used to simulate, test, and optimise real-world systems. This helped me realise how virtual modelling could be applied to enhance crash survivability through smarter, adaptive safety systems.

How it works

Emergency life-saving system where components of plane seats are integrated into removable, modular pods that separate in the event of a crash to save lives. These pods are hardened, fire-resistant, and equipped with parachutes and buoyancy aids. When a crash is imminent, smart sensors detect the threat and trigger a mechanism that detaches the pods from the aircraft structure. Each pod accommodates a group of seats rather than a single one, making the system more practical and space-efficient for real aircraft cabins. During a steep descent or loss of control, the pods detach, deploy parachutes, and either float or land safely based on conditions. We use Digital Twin technology to create a real-time virtual model of the system to simulate crash scenarios and test parameters such as release timing, descent speed, stability, and heat resistance. This avoids physical prototyping, reduces costs, and supports sustainability.

Design process

The design process began by analyzing real-world crash data, especially the Air India Flight 171 tragedy (2025), which highlighted the urgent need for improved in-flight safety. The idea evolved into developing modular, fire-resistant survival pods to replace traditional aircraft seats. These pods are designed to detach and protect passengers during extreme emergencies such as mid-air failure or crash landings. The initial concept had one pod per seat, but space and weight analysis led to grouping seats into larger shared pods, making the design more practical. I began with concept digital modeling using tools like Fusion 360 to visualize the structure. Simulations will carried out in Siemens Plant Simulation and Ansys Twin Builder to understand stress, deployment speed, and environmental factors. A Digital Twin is being built to mimic real-life behavior virtually, enhancing both safety and sustainability. The system will include sensors and an AI-based predictive algorithm. Currently, the design is ongoing, Creating a physical prototype is challenging but necessary for validation. It requires testing materials, impact resistance, and real-world functionality. Despite these challenges, this step is vital to turn simulation into reality.

How it is different

What makes this design unique is that it replaces traditional aircraft seats with self-contained, fire-resistant survival pods a concept not currently used in commercial aviation. Unlike conventional safety systems like life vests, oxygen masks, or reinforced cabins, these pods are individual, modular units designed to protect each passenger in the event of a severe crash, fire, or emergency landing. Pod is equipped with built-in sensors to detect heat, smoke, and rapid altitude drops. When triggered, the pod automatically locks down, cushions impact, and isolates the passenger from external hazards. A key differentiator is the use of a Digital Twin, which allows continuous simulation and improvement of pod performance in real-time, even before physical deployment. Unlike existing solutions that rely solely on crew action or generalised aircraft-wide systems, this concept is personalised, predictive, and pre-emptive using AI-based alerts for early action.

Future plans

The next step is to complete the digital twin simulations. I aim to collaborate with aerospace labs, universities, or startups to refine the design. Long-term, I plan to patent the concept, seek government or private funding, and explore retrofitting options for existing aircraft. My goal is to make this innovation commercially viable, regulatory-approved, and a standard for future aircraft safety, ultimately saving lives in critical emergencies.

Awards