This study addresses the limitations of traditional teaching models in the aircraft design course in fostering higher-order thinking skills, proposing and validating an innovative teaching path based on digital twin technology. The path features a three-stage progressive learning framework, starting from basic conceptual modeling, advancing to iterative analysis under multi-objective constraints, and culminating in open-ended innovative design. By integrating professional tools such as OpenVSP and ANSYS, an immersive virtual learning environment is constructed, transforming abstract structural design and performance analysis principles into interactive and perceptible inquiry processes. In teaching practice, this study uses the multi-objective collaborative design of an aircraft wing’s primary load-bearing structure as a typical case study, guiding students to actively adjust parameters, analyze results, and optimize decisions by setting constraints and performance indicators with real-world engineering backgrounds. Effectiveness evaluations show significant improvements in students’ analytical rigor, iteration depth, and multi-objective trade-off capabilities during the design process. Qualitative analysis further reveals a significant shift in students’ thinking patterns from passive knowledge acceptance to active exploration of solutions. This study provides an operable implementation framework for teaching reforms in core courses of aerospace engineering majors, demonstrating the application potential of cutting-edge digital technologies in promoting deep learning and innovation capacity building.