What Prime Contractors Should Look for in a Simulated Avionics Partner

Selecting a supplier for a flight-simulation program involves more than finding a company that can manufacture a panel, instrument, or display.

Prime contractors need a simulated avionics partner that understands the full program lifecycle—from early engineering and prototype development through repeatable production, documentation, delivery, and long-term support.

The right partner should strengthen the program, reduce technical and schedule risk, and remain responsive when requirements change. Before selecting a simulated avionics supplier, primes should evaluate these six core capabilities.

Simtek F-16 ATC-961 UHF RADIO

1. Proven Engineering Capability

A qualified simulated avionics partner must be able to do more than build from a completed drawing package.

Simulation programs frequently begin with incomplete technical data, legacy hardware, limited access to aircraft components, or performance requirements that must be translated into a practical training solution. The supplier should be capable of evaluating those requirements and developing hardware that achie

ves the required level of fidelity without adding unnecessary cost or complexity.

That includes the ability to:

• Develop custom instruments, panels, displays, and control assemblies

• Reproduce obsolete or unavailable components

• Interpret customer specifications and statements of work

• Develop electrical and mechanical interfaces

• Support prototype and first-article development

• Recommend simulation-specific alternatives to aircraft hardware

• Incorporate maintainability into the design

A strong engineering team should also understand that not every training device requires identical hardware. A desktop trainer, fixed-base device, procedural trainer, and full-flight simulator may each require a different balance of fidelity, cost, durability, and functionality.

The partner should be able to engineer to the training requirement—not simply copy the aircraft at any cost.

2. Disciplined Configuration Control

Configuration control is essential when hardware will be installed across multiple devices, training centers, aircraft configurations, or production lots.

Prime contractors should confirm that the supplier has a documented process for controlling:

• Drawings and engineering data

• Bills of material

• Software and firmware revisions

• Approved component substitutions

• Customer-directed changes

• Manufacturing work instructions

• Inspection and test requirements

• As-built configuration records

  
  

Without disciplined configuration control, two assemblies produced under the same part number may perform differently or contain undocumented component changes.

That creates avoidable problems during integration, acceptance testing, field support, and future replacement orders.

A dependable simulated avionics partner should be able to identify exactly what was manufactured, which revision was used, what testing was completed, and how future units will remain consistent with the approved configuration.

3. Repeatable Manufacturing

A successful prototype does not automatically translate into a successful production program.

Prime contractors should evaluate whether the supplier has the people, equipment, quality controls, and production processes needed to manufacture the same product repeatedly.

Important capabilities may include:

• CNC machining and fabrication

• Precision assembly

• Wiring and harness integration

• Paint and finishing

• Laser marking and engraving

• Lightplate manufacturing

• Electronics integration

• In-process inspection

• Final assembly and quality control

Whenever possible, primes should look for a partner that controls multiple manufacturing processes under one roof. Reducing unnecessary handoffs between outside vendors can improve communication, shorten reaction time, and provide greater control over quality and schedule.

Repeatability is especially important when the program moves from a first article into multiple devices or long-term production. The tenth unit should match the approved first unit in appearance, fit, function, and performance.

4. Defined Inspection and Testing

Testing should be treated as part of the manufacturing process—not as an activity performed only after something fails.

Before awarding a program, the prime contractor should understand how the supplier will verify the finished hardware. Depending on the product and program requirements, testing may include:

• Dimensional inspection

• Visual and workmanship inspection

• Electrical continuity testing

• Functional testing

• Display and lighting verification

• Communication-interface testing

• Environmental testing

• Vibration or thermal testing

• Acceptance test procedures

• First-article inspection

The supplier should also be able to develop testing around the actual program requirement.

A static cockpit panel does not require the same validation as an interactive avionics assembly used in a high-utilization training device. The testing plan should reflect the hardware’s function, operating environment, interface, and expected service life.

Clearly defined acceptance criteria help both the prime and the supplier avoid misunderstandings at delivery.

5. Complete and Usable Documentation

Good documentation protects the program long after the first hardware delivery.

The required documentation will vary by contract, but prime contractors should establish expectations early. Deliverables may include:

• Mechanical drawings

• Electrical schematics

• Interface control documents

• Bills of material

• Acceptance test procedures

• Inspection records

• Certificates of conformance

• Installation information

• Operating or maintenance instructions

• Configuration records

• Revision histories

The value of documentation is not measured by the number of pages delivered. It should be accurate, controlled, relevant, and usable by the engineers and technicians who will integrate and support the product.

Documentation requirements should also be clearly defined in the statement of work and proposal. This ensures that the supplier understands which data must be delivered, when it is required, and what rights apply to it.

6. Long-Term Support and Obsolescence Management

Flight-training devices often remain in service far longer than many of the electronic components used to build them.

A simulated avionics partner should therefore be evaluated not only on its ability to deliver new hardware, but also on its ability to support that hardware over time.

Prime contractors should ask:

• Can the supplier reproduce the same configuration several years later?

• How are discontinued components identified and managed?

• Can obsolete simulator hardware be redesigned or replaced?

• Are repair and evaluation services available?

• Can the supplier support small replacement quantities?

• Will technical personnel remain available after delivery?

• How are form, fit, function, and interface compatibility maintained?

A low initial price provides little value if the supplier cannot support replacement hardware, configuration changes, or component obsolescence later in the program.

Long-term support should be considered during supplier selection—not after the first field failure.

Selecting a Partner That Strengthens the Program

The best simulated avionics suppliers operate as an extension of the prime contractor’s program team.

They communicate clearly, identify risks early, control the approved configuration, manufacture consistently, document their work, and remain available throughout the product lifecycle.

For more than four decades, Simtek has supported military and commercial flight-simulation programs with custom simulated avionics, instruments, panels, displays, lightplates, and integrated hardware assemblies.

Our engineering and manufacturing capabilities allow us to support projects ranging from individual replacement components to complete cockpit module assemblies.

Whether the requirement involves a new training device, an obsolete simulator component, or a production program requiring repeatable hardware, Simtek is ready to support the mission.

Discuss Your Next Simulation Program

Looking for a simulated avionics partner for an upcoming flight-training program?

Contact Simtek to discuss your technical requirements, program schedule, documentation needs, and long-term support objectives.

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