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Weapon Systems Testing: DOD Needs to Update Policies to Better Support Modernization Efforts

GAO-26-107009 Published: Dec 11, 2025. Publicly Released: Dec 11, 2025.
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Fast Facts

As part of its goal to deliver weapon systems to the battlefield at a faster pace, the Department of Defense plans to modernize its approach to testing new systems. Plans include broader use of digital engineering tools and a highly skilled workforce.

Leading companies get complex systems to market quickly using iterative testing processes. We compared these companies' practices to DOD testing policies. We found greater government application of leading companies' practices could improve weapons testing, contributing to faster and more efficient acquisitions.

Our 13 recommendations to DOD address this issue.

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A hand extends away from the viewer toward a blurred city skyline. A 3-D rendering of an unknown device hovers in the air above the hand like a hologram.

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Highlights

What GAO Found

The Department of Defense (DOD) identified test and evaluation modernization as a crucial part of its effort to get capabilities to warfighters faster. DOD organizations, including the Office of the Secretary of Defense and the military departments, have undertaken modernization planning efforts with varying areas of focus and levels of detail. Nonetheless, these plans share themes, including the use of digital engineering tools and highly skilled workforces.

GAO’s analysis of DOD-wide test and evaluation policies found they were not fully consistent with selected leading practices for product development as applied to test and evaluation: involve testers early, conduct iterative testing, use digital twins and threads, and obtain user feedback iteratively. These policies contained some tenets of the leading practices, particularly for the software acquisition and urgent capability acquisition pathways. However, these leading practices were largely not reflected in the policies for programs in the major capability acquisition and middle tier of acquisition pathways, which account for the majority of DOD spending on weapon systems acquisition.

Key DOD-wide Weapon Systems Testing Policies Fall Short of Selected Leading Practices

Key DOD-wide Weapon Systems Testing Policies Fall Short of Selected Leading Practices

Further, GAO found that DOD’s digital engineering policy and the test and evaluation section of DOD’s systems engineering policy do not describe specific processes to ensure application of leading practices to testing.

GAO also found that military department-level test and evaluation policies generally did not reflect the leading practices beyond the level found in DOD-wide policies. GAO similarly found that these leading practices were not reflected in key program documents, like acquisition strategies and test strategies, for selected weapon systems acquisition programs it reviewed.

DOD has a unique opportunity to not only retool its existing test and evaluation enterprise, but to redefine the role that enterprise can play in enabling faster delivery of relevant capabilities to warfighters. Fully incorporating leading practices into policies relevant to weapon system test and evaluation could help pivot the test enterprise’s current reactive role to a proactive one, informing and aiding defense acquisition efforts.

Why GAO Did This Study

DOD has yet to realize its goal to rapidly develop weapon systems to get capabilities to the warfighter when needed. DOD acquisition programs have identified challenges discovered during test and evaluation as contributing to delays in development.

A House committee report includes a provision for GAO to assess how DOD is modernizing weapon system test and evaluation. GAO’s report (1) describes DOD’s plans to modernize test and evaluation to deliver capabilities faster to the warfighter, and (2) assesses the extent to which DOD-wide and military department policies for test and evaluation reflect selected GAO leading practices for product development.

To do this work, GAO assessed DOD test and evaluation modernization plans and policies and weapon system acquisition documentation. GAO visited three military department test organizations to observe tools in practice. GAO also interviewed DOD and military department officials from test organizations and other entities.

Recommendations

GAO is making 13 recommendations, including that the Secretary of Defense and the Secretaries of the Air Force, Army, and Navy each should revise weapon system test and evaluation policies and other related policies to reflect selected leading practices for product development. Specifically, revisions should require involvement of testers in acquisition strategies; iterative approaches to testing, including use of digital twins and threads; and ongoing end user input. DOD concurred with seven recommendations, partially concurred with five recommendations, and did not concur with one recommendation. GAO continues to believe all 13 of its recommendations are valid, as discussed in this report.

Recommendations for Executive Action

Agency Affected Recommendation Status
Department of Defense The Secretary of Defense should ensure that the Under Secretary of Defense for Research and Engineering and the Director of Operational Test and Evaluation revise their weapon system test and evaluation, digital engineering, and systems engineering policies to fully reflect leading practices for product development by requiring developmental and operational testers to provide input into the development of acquisition strategies, including on testing-related topics such as the use of and access to digital twins and digital threads. (Recommendation 1)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of Defense The Secretary of Defense should ensure that the Under Secretary of Defense for Research and Engineering and the Director of Operational Test and Evaluation revise their weapon system test and evaluation, digital engineering, and systems engineering policies to fully reflect leading practices for product development by requiring developmental and operational testers to develop test strategies and test plans that reflect an iterative, integrated testing approach enabled by digital twins and digital threads to support delivery of minimum viable products. (Recommendation 2)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of Defense The Secretary of Defense should ensure that the Under Secretary of Defense for Research and Engineering and the Director of Operational Test and Evaluation revise their weapon system test and evaluation, digital engineering, and systems engineering policies to fully reflect leading practices for product development by requiring developmental and operational testers to develop and implement test strategies and test plans that incorporate end user agreements that detail a process for obtaining ongoing user input and feedback for the system under test. (Recommendation 3)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Air Force The Secretary of the Air Force should, as the Air Force revises its weapon system test and evaluation policy, ensure that policy fully reflects leading practices for product development by requiring developmental and operational testers to provide input into the development of acquisition strategies, including on testing-related topics such as the use of and access to digital twins and digital threads. (Recommendation 4)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Air Force The Secretary of the Air Force should, as the Air Force revises its weapon system test and evaluation policy, ensure that policy fully reflects leading practices for product development by requiring developmental and operational testers to develop test strategies and test plans that reflect an iterative, integrated testing approach enabled by digital twins and digital threads to support delivery of minimum viable products. (Recommendation 5)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Air Force The Secretary of the Air Force should, as the Air Force revises its weapon system test and evaluation policy, ensure that policy fully reflects leading practices for product development by requiring developmental and operational testers to develop and implement test strategies and test plans that incorporate end user agreements that detail a process for obtaining ongoing user input and feedback for the system under test. (Recommendation 6)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Army The Secretary of the Army should, as the Army revises its weapon system test and evaluation policy, ensure that policy fully reflects leading practices for product development by requiring developmental and operational testers to provide input into the development of acquisition strategies, including on testing-related topics such as the use of and access to digital twins and digital threads. (Recommendation 7)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Army The Secretary of the Army should, as the Army revises its weapon system test and evaluation policy, ensure that policy fully reflects leading practices for product development by requiring developmental and operational testers to develop test strategies and test plans that reflect an iterative, integrated testing approach enabled by digital twins and digital threads to support delivery of minimum viable products. (Recommendation 8)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Army The Secretary of the Army should, as the Army revises its weapon system test and evaluation policy, ensure that policy fully reflects leading practices for product development by requiring developmental and operational testers to develop and implement test strategies and test plans that incorporate end user agreements that detail a process for obtaining ongoing user input and feedback for the system under test. (Recommendation 9)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Navy The Secretary of the Navy should revise the military department's weapon system test and evaluation policy to fully reflect leading practices for product development by requiring developmental and operational testers to provide input into the development of acquisition strategies, including on testing-related topics such as the use of and access to digital twins and digital threads. (Recommendation 10)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Navy The Secretary of the Navy should revise the military department's weapon system test and evaluation policy to fully reflect leading practices for product development by requiring developmental and operational testers to develop test strategies and test plans that reflect an iterative, integrated testing approach enabled by digital twins and digital threads to support delivery of minimum viable products. (Recommendation 11)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of the Navy The Secretary of the Navy should revise the military department's weapon system test and evaluation policy to fully reflect leading practices for product development by requiring developmental and operational testers to develop and implement test strategies and test plans that incorporate end user agreements that detail a process for obtaining ongoing user input and feedback for the system under test. (Recommendation 12)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.
Department of Defense The Secretary of Defense should ensure that the Under Secretary of Defense for Acquisition and Sustainment revises its weapon system acquisition policies to require that such acquisition programs obtain and incorporate input from developmental and operational testers in the development of acquisition strategies, including on testing-related topics such as the use of and access to digital twins and digital threads. (Recommendation 13)
Open
When we confirm what actions the agency has taken in response to this recommendation, we will provide updated information.

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Topics

Developmental testingSystems acquisitionMilitary forcesBest practicesEngineeringWeapon systemsSystems testingProduct developmentOperational testingDefense acquisition programs