This manuscript presents a design exploration and technology assessment process for military aerospace vehicles. The new process utilises physics-based analyses and a distributed collaborative computational environment to predict vehicle performance which in turn is used in mission level simulations to assess the impact of a given configuration or technology on the combat effectiveness of a system. The new process will be executable within the same time and resource constraints of the traditional process. This enables AFRL technology developers to have a quantifiable and traceable trail of the impact of their technologies on system performance parameters such as weight, lift, and drag into terms that Air Force leadership uses to measure system effectiveness -lethality, survivability, sustainability, and affordability. This leads to well informed decisions concerning technology investment and achievable capabilities.Keywords: design process; multi-disciplinary design optimisation; aerospace vehicle design; collaborative design; technology assessment. This paper is a revised and expanded version of a paper entitled 'Physics-based distributed collaborative design for aerospace vehicle development and technology assessment' presented at the 20th ISPE International Conference on Concurrent