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Simtek Mechanical & Electrical Engineering: Excellence Is Engineered

  • 11 minutes ago
  • 4 min read
SIMTEK C-130 FLIGHT SIMULATOR PANEL DESIGN
SIMTEK C-130 FLIGHT SIMULATOR PANEL DESIGN

In flight simulation, excellence is not accidental. It is engineered.


Every realistic avionics panel, display, control, lightplate, and cockpit component begins with a deep understanding of how the real aircraft system looks, feels, operates, and performs in a training environment. At Simtek, mechanical and electrical engineering work together to turn complex requirements into reliable, manufacturable, simulator-ready products.


For decades, Simtek has supported the flight simulation industry with custom simulated avionics and cockpit components designed for commercial, military, and defense training programs. From high-fidelity replicas to cost-effective trainer components, our engineering process is built around accuracy, functionality, durability, and long-term support.


Mechanical Engineering That Defines the Experience

Mechanical design plays a major role in simulator realism. A cockpit component must do more than fit into a panel. It must feel correct to the operator, install properly into the simulator, support repeated use, and maintain the visual and physical details required for effective training.


Simtek’s mechanical engineering team develops products that support form, fit, function, ergonomics, and manufacturability. This includes custom housings, bezels, knobs, switch guards, panel layouts, brackets, lightplates, mounting features, and mechanical assemblies designed specifically for simulator applications.


Our mechanical engineering capabilities support:

  • High-fidelity cockpit panels and avionics replicas

  • Custom machined and fabricated simulator components

  • Aircraft-style bezels, knobs, switches, and controls

  • Lightplate and backlighting integration

  • Mounting and enclosure design

  • Ergonomic control layouts

  • Reverse engineering support

  • Manufacturable designs for repeat production

  • Durable assemblies built for training environments


Whether the requirement is a single custom panel or a larger cockpit assembly, Simtek engineers each product with the end user, simulator integrator, and production process in mind.


Electrical Engineering That Brings Products to Life

A simulator component must not only look correct. It must function reliably.


Simtek’s electrical engineering team supports the design and integration of electronics, lighting, displays, switch logic, wiring, and interfaces required to make simulator products operate within the larger training system. From simple discrete panels to more complex avionics-style products, Simtek develops solutions that are practical, dependable, and built for simulator use.


Our electrical engineering capabilities support:

  • Serial Interface

  • Discrete I/O

  • RS232

  • RS485

  • RS422

  • USB

  • Ethernet

  • PoE, Power over Ethernet

  • ARINC 429

  • CANbus


In addition to:

  • Circuit design and electrical integration

  • Display and indicator functionality

  • Switch, encoder, and input logic

  • Backlighting and dimming control

  • Wiring harness design

  • Interface support for simulator systems

  • Internal electronics design

  • Functional testing and troubleshooting

  • Electrical documentation for production and sustainment


This electrical expertise allows Simtek to provide products that not only represent the aircraft visually but also respond and perform as part of the training environment.


Engineering and Manufacturing Working Together

One of Simtek’s strongest advantages is that engineering and manufacturing work closely together under one roof. Our engineers do not design products in isolation.


They work directly with production, machining, assembly, quality, purchasing, and test personnel to ensure each design can be built, inspected, supported, and repeated.


This connection between engineering and manufacturing helps reduce risk, improve communication, and create a smoother path from concept to production.

For customers, that means practical designs, fewer surprises, and simulator products that are engineered with real-world manufacturing in mind.


Built for High-Fidelity Training

Some simulator components must closely replicate the real aircraft. These products need the correct appearance, size, control spacing, lighting, tactile feel, and functional behavior. In these applications, fidelity matters because the training objective depends on the physical experience of operating the equipment.


Simtek supports high-fidelity products for programs that require realistic cockpit interaction, accurate visual representation, and durable training hardware. Our experience with simulated avionics, panels, displays, instruments, and controls allows us to help customers meet demanding simulator requirements.


When training value depends on realism, Simtek engineers products to look right, feel right, and function right.


Low-Fidelity Products Backed by Simtek Quality

Not every component in a trainer requires full aircraft-level fidelity. Some programs need lower-fidelity products to support procedural training, familiarization, budget control, or early-stage trainer development.


Simtek also offers low-fidelity products backed by the same Simtek quality standard. This allows customers to choose the right level of fidelity for each part of the simulator without sacrificing reliability or professional manufacturing.


By offering both high-fidelity and low-fidelity solutions, Simtek helps simulator builders balance realism, cost, schedule, and training needs.


Reverse Engineering and Custom Product Development

Many simulator programs involve legacy aircraft, obsolete components, limited technical data, or hardware that is difficult to source. In these cases, Simtek can support reverse engineering and custom development when customer-furnished equipment, drawings, photographs, measurements, or 3D scan data are available.


Our mechanical and electrical engineering teams can evaluate the available information, develop manufacturable designs, and create simulator components that support the required training mission.


This capability is especially valuable for older aircraft, replacement simulator hardware, cockpit modernization efforts, and custom trainer builds.


Designed for Durability and Long-Term Support

Simulator products are used repeatedly in demanding training environments. They must be durable, serviceable, and repeatable.


Simtek designs products with long-term support in mind. Our engineering process considers assembly, inspection, replacement parts, testing, documentation, and sustainment from the beginning of the project.


Key design considerations include:

  • Repeatable production

  • Ease of assembly

  • Maintainability

  • Functional testing

  • Replacement part support

  • Documentation control

  • Long-term simulator sustainment


Customers rely on Simtek not only to deliver the product, but to support it throughout the life of the program.


Why Customers Choose Simtek

Since 1978, Simtek has delivered simulated avionics and cockpit components for the flight simulation industry. Our mechanical and electrical engineering capabilities allow us to support a wide range of training programs, from high-fidelity aircraft replicas to cost-effective trainer components.


Customers choose Simtek because we understand the connection between engineering, manufacturing, realism, reliability, and training value.

We know that a simulator component must be more than a part. It must support the mission.


Excellence Is Engineered

At Simtek, excellence is engineered through experience, attention to detail, and a commitment to building products that meet the needs of today’s flight simulation programs.


Whether you need a custom avionics panel, cockpit control, display assembly, lightplate, mechanical housing, electrical interface, or complete simulator component, Simtek brings mechanical engineering, electrical engineering, manufacturing, quality, and decades of simulation experience together to support your program.


Contact Simtek today to discuss your next simulator engineering requirement.


 
 
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