Built Tougher Than the Real Thing: Why Simtek Simulated Avionics Are More Robust Than OEM Hardware

C-130 ENGINE FIRE PANEL

In the real aircraft, many cockpit controls are designed for rare, high-consequence use. In the simulator, those same functions get used over and over and over again.

That difference in usage is exactly why Simtek simulated avionics are engineered to be more robust than many OEM components.

Our panels, switches, and controls have to survive years of constant training abuse while still feeling realistic and behaving correctly every time.

The 737 Fire Handle Example: Once in a Lifetime vs. Thousands of Times

Take a 737 engine fire handle as a simple example:

• In the real world: A fire handle might only be pulled once in an entire aircraft’s service life—and in a perfect world, never.

• In the simulator:That same action may be practiced hundreds or even thousands of times per year.Every new crew, every recurrent check, every emergency drill involves pulling that handle to simulate an engine fire.

In training, this is exactly what you want—repe

tition builds muscle memory and confidence.But it also means the hardware is subjected to far more cycles, force, and wear than the OEM component was ever intended to see in real service.

That’s where Simtek’s expertise comes in.

Designed for the Harshest Training Abuse

Simtek designs simulated avionics hardware with the true duty cycle of a simulator in mind:

• Repetitive, high-cycle use

• Firm pulls, twists, and pushes from different crews and instructors

• Daily operation across long schedules and heavy training loads

Our components are engineered to:

• Handle thousands of actuations without losing feel or function

• Maintain mechanical integrity under repeated stress

• Keep their tactile realism even after years of use

Whether it’s a fire handle, gear lever, guarded switch, rotary selector, or pushbutton, we treat every control like it’s going to be abused in training—because it will be.

Beyond OEM Expectations: Simulator-Grade Durability

OEM aircraft hardware is designed for real-world mission profiles, where many controls:

• Are used infrequently

• See relatively low cumulative wear

• Are surrounded by strict operational procedures

Simulators are different. They’re training environments, not one-time emergency scenarios.

Simtek’s approach is to go beyond OEM expectations by:

• Reinforcing mechanical designs where training use is harsher

• Selecting materials and internal mechanisms suited for high-cycle environments

• Validating feel and durability with repeated actuation and stress during development

The goal is simple:

When a crew member pulls that simulated 737 fire handle for the 500th time, it should still feel solid, predictable, and real.

High-Fidelity Feel, Simulator-Grade Strength

We never trade realism for strength—we deliver both:

• High-fidelity feel – realistic detents, resistance, and motion

• Simulator-grade robustness – built to handle the toughest training cycles

That balance is what makes Simtek hardware ideal for:

• Full-flight simulators

• Flight training devices (FTDs)

• Emergency procedure trainers

• Part-task trainers and mockups

Simtek’s Expertise: Built for Abuse, Built for Training

At Simtek, we know that simulated avionics live a harder life than their real-world counterparts. That’s why we engineer our components from day one to:

• Withstand the harshest training abuse

• Maintain consistent performance and feel

• Reduce downtime and keep simulators online and productive

From a 737 fire handle to the smallest guarded switch, our philosophy is the same:

If it’s going into a simulator, it has to be tougher than the real thing.

If your training devices are wearing out controls faster than you’d like, or you’re tired of replacing fragile components, Simtek’s simulator-grade simulated avionics are built to take the abuse—and keep your training mission moving.