Reverse Engineering Obsolete Components: Keeping Your Flight Simulators Operational

In the world of flight simulation, one of the biggest challenges isn’t always new technology—it’s old hardware.

As aircraft evolve and OEMs discontinue parts, many simulators are left relying on obsolete components and subassemblies that are no longer supported. When those parts fail, training devices can be grounded. Programs are then forced to choose between expensive redesigns or limited workarounds.

That’s where Simtek comes in.

We specialize in reverse engineering obsolete components for simulated avionics and the subassemblies used inside them. This helps you keep your simulators running without sacrificing fidelity.

When OEM Support Ends, Your Training Shouldn’t

Over time, OEMs may:

• Discontinue specific avionics units or assemblies

• Stop supporting older part numbers

• Move on to new product lines and technologies

  
  

Many simulators still depend on those original designs to stay certified, consistent, and usable.

Simtek helps bridge this gap by:

• Taking existing, obsolete parts and reverse engineering them

• Recreating form, fit, and function so replacements integrate seamlessly

• Providing long-term support where OEMs no longer do

  
  

The result? You can extend the life of your simulator instead of scrapping or completely re-architecting it.

Reverse Engineering Down to the Details

Our reverse engineering process is built around precision and respect for the original design.

Simtek’s team can:

• Analyze mechanical, electrical, and labeling details of the original unit

• Recreate panels, enclosures, and internal structures using 3D modeling and in-house machining

• Replicate electrical interfaces, connectors, and I/O behavior to match existing wiring and systems

• Develop functionally equivalent subassemblies (switch matrices, indicator clusters, light plates, etc.)

  
  

We don’t just copy the look—we replicate how the component behaves inside your simulator.

Supporting Simulated Avionics & Subassemblies

We can reverse engineer:

• Simulated control panels and faceplates

• Internal subassemblies such as PCB carriers, switch boards, and indicators

• Mechanical components like bezels, brackets, knobs, and actuators

• Interface modules that manage signals into your existing I/O systems

  
  

Whether you are missing a single obsolete unit or trying to support an entire family of aging hardware, we can help you build a sustainable, supportable path forward.

Drop-In Replacements, Minimal Disruption

One of our primary goals is to create drop-in replacements that:

• Mount to the same holes and structures

• Use the same or equivalent connectors

• Maintain existing software, behavior, and user interaction

  
  

By preserving form, fit, and function, we help you:

• Avoid major rewiring or re-software efforts

• Reduce downtime during transitions

• Keep training consistent for instructors and crews

  
  

Your simulator keeps working the way people expect—only now with parts you can actually support.

Extending the Life of Your Simulation Investment

Full redesigns are sometimes necessary—but not every problem requires one. Reverse engineering obsolete components with Simtek can:

• Extend the life of legacy simulators

• Protect your investment in existing training devices

• Smooth the path for gradual upgrade and refresh programs

  
  

Instead of choosing between “live with the failure” or “spend big on a full rebuild,” you gain a third option: modern, supportable replacements that mimic the original hardware.

If OEMs have moved on but your simulator hasn’t, Simtek can help you reverse engineer and replace obsolete components and subassemblies—so your training doesn’t have to stop when the original parts do.

The Future of Flight Simulation

As we look ahead, the landscape of flight simulation will continue to evolve. New technologies will emerge, and the demand for realistic training will grow. However, the challenge of obsolete components will remain.

Simtek is committed to staying at the forefront of this industry. We will continue to innovate and provide solutions that meet the needs of our clients. Our goal is to ensure that your training devices remain operational and effective.

Why Choose Simtek?

Choosing Simtek means choosing reliability. We understand the unique challenges faced by flight simulator manufacturers and training organizations. Our expertise in reverse engineering ensures that you receive high-quality replacements for obsolete components.

We are dedicated to providing supportable solutions that enhance your training experience. Our team is ready to work with you to find the best options for your specific needs.

In conclusion, don't let obsolete components hinder your training programs. Contact Simtek today to learn how we can help you maintain the integrity and functionality of your flight simulators. Together, we can ensure that your training continues without interruption.