Reducing Total Ownership Cost in Simulated Avionics -
- ccowley
- Nov 13
- 5 min read
Updated: 5 days ago
Design Choices That Save Money Year After Year
In flight simulation, the real cost of hardware isn’t just the purchase order you sign. It’s everything that follows:
Spares
Obsolescence
Downtime
Engineering churn
Re-qualification and paperwork
That’s total ownership cost (TOC)—and for a long-lived simulator, it can quietly dwarf the original hardware price.
At Simtek, we’ve spent over four decades designing simulated avionics, displays, and control panels specifically to keep TOC low without compromising fidelity. Our hardware is virtually flying in commercial and military trainers worldwide—from classroom devices to Level D full flight simulators. Many of those systems are still running strong after decades in service.
This post breaks down how smart design choices translate into real savings year after year. It also explains how Simtek incorporates TOC thinking into everything we build.
What “Total Ownership Cost” Really Means in a Simulator Program
For a typical simulator program, TOC includes:
Acquisition – NRE, hardware, integration.
Integration & certification support – engineering time, I/O, documentation, qualification.
Operations & maintenance – spares, repairs, troubleshooting, technician time.
Obsolescence management – redesigns, form/fit/function replacements, re-qualification.
Downtime & lost training – schedule slips, missed training slots, recovery costs.
A control panel, instrument, or display that’s cheaper on day one but:
Fails more often
Is hard to service
Has one-off parts that go obsolete
…quickly becomes the most expensive part of your cockpit.
By contrast, a unit that’s modular, maintainable, and built on long-life architectures pays for itself repeatedly.
Simtek Design Choice: Engineer for Maintenance from Day One
Simtek designs for the maintainer, not just the drawing:
Line-replaceable modules (LRUs): Plug-and-play boards and subassemblies allow for quick fault isolation and swaps.
Front-serviceable construction: Access to critical electronics via removable bezels and smart harness routing.
Clear, complete documentation: Data sufficient for installation, operation, maintenance, testing, and repair to component level is delivered with every Simtek product when applicable.
That’s why many of our customers standardize on Simtek hardware across fleets. Predictable maintenance beats surprise heroics every time.
Simtek Design Choice: Use Common Architectures, Not One-off Experiments
A major driver of lifetime cost is how “unique” your hardware is. Simtek deliberately designs around common, proven building blocks:
Shared PCB platforms across different product families.
Standardized interface options (RS-232/422/485, Ethernet/PoE, USB).
Reusable mechanical footprints and mounting schemes.
This approach allows us to:
Shorten lead times: Less custom re-inventing per program.
Simplify spares: Support multiple LRUs.
Reduce engineering cost: Proven architectures need less re-qualification and debug.
For you, this means lower NRE and a more manageable long-term support picture—especially when fielding multiple simulators across several aircraft types.
Simtek Design Choice: Build to Simulation Requirements, Not Airborne Overkill
We appreciate real avionics, but simulation hardware doesn’t need to carry the weight and certification burden of airborne equipment to deliver high-fidelity training. Simtek optimizes each design for training device use, not unnecessary extremes:
Materials and components selected for 24/7 simulator duty.
Thoughtful derating and cooling ensure electronics live long lives in bays and instructor stations.
Rugged enough for constant use, but not “gold-plated” where it adds cost without training value.
The result: you still get the look, feel, and behavior of the real aircraft, but with hardware that’s cheaper to buy, easier to service, and more economical to sustain over decades.
Simtek Design Choice: Design for Obsolescence Management
No simulator program is immune to component EOL notices. The question is: are you ready for them?
Simtek treats obsolescence as a design requirement:
Long-life component selection: Preference for stable, widely supported parts with multiple vetted sources.
Clear separation between I/O and computing: So a processing card can be updated while interfaces and mechanicals stay constant.
Form / fit / function drop-in replacements: When redesign is necessary, we aim for slide-in replacements that minimize re-integration and re-qualification work.
Because we keep full design and manufacturing in-house in Euless, Texas, we can respond quickly when something changes—without sending you back to square one.
Simtek Design Choice: Quality and Support That Outlive the Program
TOC isn’t just about hardware; it’s also about how your vendor shows up over the life of the device.
Simtek backs our products with:
High-reliability manufacturing standards: Workmanship per J-STD-001 and IPC-A-610 where applicable.
Lifetime technical support and robust warranties on many panel products.
Direct access to the engineers who designed your hardware when you’re troubleshooting edge cases.
Our Quality / Terms page outlines the philosophy behind that commitment. When combined with 45+ years of focus on flight simulation and over 9,500 part numbers delivered into training devices worldwide, you get something unusual in this space: a partner who’ll still be there when your device hits mid-life refresh.
How Simtek Specifically Drives Down TOC for Your Program
Here’s how all of this comes together when you choose Simtek for your cockpit hardware:
Lower integration friction: Familiar, documented interfaces make it easier for your I/O engineers to plug into the host. Detailed ICDs and drawings reduce the back-and-forth during integration.
Reduced spares burden: Common modules across control panels, instruments, and displays mean fewer unique spares. Our long production history makes it realistic to support devices for decades—not just a product cycle or two.
Fewer costly surprises mid-program: Proactive obsolescence planning and redesigns that respect your mechanical and certification baselines. Stable product baselines don’t require constant rework every time a component changes.
Less downtime, more training: Quick fault isolation and LRU swaps translate into faster MTTR and more time with pilots in the seat. Lifetime technical support means when something odd happens, you have experts who know the hardware inside out.
When you step back and look at the full lifecycle of a device, Simtek’s approach often turns a “mid-pack” quote on day one into the lowest-cost solution over 10–20 years of service.
Why Simtek Is Uniquely Positioned to Lead on TOC in Simulated Avionics
A lot of companies dabble in simulation. Simtek was built around it.
Simulation-first DNA: We design specifically for flight simulators and training devices, not retrofitted airborne hardware.
Complete product stack: From instruments, control panels, and displays to custom solutions beyond avionics, we can harmonize TOC across your entire device.
In-house engineering + manufacturing: Mechanical, electrical, software, and fabrication under one roof give us precise control over quality, cost, and obsolescence.
Ready to Talk About Lowering TOC on Your Next Project?
Whether you’re refreshing a legacy device, building a new full-flight platform, or standing up a family of FTDs, our team can help you model lifecycle cost, not just line-item price.
Contact us:
Simtek: 817‑283‑1801
Additional Insights on Cost-Effective Design Choices
Understanding the Importance of TOC
Total Ownership Cost (TOC) is a critical metric in evaluating the long-term value of simulator hardware. It encompasses all expenses associated with the lifecycle of the equipment. Understanding TOC helps organizations make informed decisions that can lead to significant savings over time.
The Role of Design in Reducing TOC
Design plays a pivotal role in TOC. Thoughtful design choices can lead to reduced maintenance costs, fewer downtime incidents, and enhanced operational efficiency. By prioritizing maintainability and modularity, Simtek ensures that our products remain cost-effective throughout their lifespan.
Future-Proofing Your Simulator Investments
Investing in simulator hardware is a long-term commitment. By choosing designs that prioritize obsolescence management, organizations can safeguard their investments against rapid technological changes. Simtek's approach to using common architectures and long-life components ensures that your simulator remains relevant and functional for years to come.
Conclusion: The Simtek Advantage
In conclusion, Simtek's commitment to low TOC through innovative design choices sets us apart in the industry. Our focus on maintainability, common architectures, and quality support ensures that our customers receive the best value over the lifespan of their simulators. When you choose Simtek, you're not just purchasing hardware; you're investing in a partnership that prioritizes your long-term success.
