The large number of new functions equipped with modern aircraft are performed together by many airframe systems arranged in different aircraft bays. Compared with aircraft structure

airframe systems have more complicated functional integration from interactions and interdependencies than physical integration. Since airframe systems are normally arranged and allocated in limited rooms

a good assembly design and reliable installations are crucial for the correct performing of aircraft overall functionalities. In SAE Aerospace Recommend Practice 4761

it introduces how a zonal safety analysis (ZSA) be used to identify and analyze the influence between airframe systems

including improper installations between system to system

system to structure

and the possible consequence of functions failure caused by those improper installations. Although SAE ARP4761 recommends that ZSA should cover the entire development process

current industrial practice mainly focuses on the application at design stage

with less application in aircraft assembly. It is also found that current ZSA process not well worked and supported in digitalization environment. This research improves ZSA process towards current digital manufacturing background by following the continuous model transmission principles

which integrates virtual reality (VR) and augmented reality (AR) together to cover conceptual design stage to manufacturing and assembly. Thanks to the digital mock-ups (DMU) used in the overall development process

it expands the application scope of ZSA method. Finally

an aircraft test-structural section is built in laboratory

and typical case studies of aircraft electrical wiring interconnect system (EWIS) integration are selected based on it to verify the feasibility of the ZSA process in virtual reality and augmented reality environment.