USAeroSim develops high-quality flight simulators using universal industrial components, along with custom-designed PCBs and software. Our simulators are engineered to meet human factors and replicate the physical design of real cockpits. Understanding the diverse demands of pilot training, we offer a range of solutions from fully enclosed, full-scale cockpits with visual systems to more cost-effective trainers that focus on avionics and familiarization.
With over 30 years of continuous development and delivery, we have established a unique standard of excellence in hardware interface design. Our proprietary software integrates seamlessly with major simulation platforms such as Prepar3D, DCS, Falcon BMS, X-Plane, and FS2020, ensuring compatibility across a wide range of training environments.
Fighter Simulators:
Helicopter Simulators:
Fixed-Wing Simulators:
Common Hardware Features Across All USAero Simulators
Panel Backplates:
Each simulator panel is equipped with custom-designed Printed Circuit Boards (PCBs), minimizing wiring between switches and LEDs. An Arduino Micro PRO serves as the interface controller, featuring a unique BIOS that assigns a specific name to each panel for seamless HID identification when connected to a computer. Every panel includes a 12V power connector and a USB port. To optimize connectivity, high-quality USB hubs consolidate all panel connections into just three USB links.
Panel Faceplates:
The faceplates are crafted from two acrylic layers: a clear bottom layer and a translucent white top layer. These are meticulously painted with a base primer and two coats of matte black, followed by laser-engraved graphics. Finally, a clear matte protective coat ensures durability and a premium finish.
Mechanical Components:
Handles, buttons, knobs and other unique features are 3D-printed using rough resin, resulting in a smooth, high-quality finish. These components are precision-drilled and assembled with screws, ensuring both functionality and durability.
Digital Gauges:
Our gauges are digital, designed and modeled as computer graphics, and displayed on a cockpit back screen. This modern approach simplifies maintenance and updates, avoiding the complexity of traditional mechanical instruments, which rely on multiple moving parts like gears and axles to function.
Computer Systems:
For entertainment or private setups, a single high-performance computer is typically sufficient to run the simulator. These systems are equipped with ultra-high specifications, often including dual GPUs, to ensure smooth operation and immersive graphics. This setup provides the necessary processing power to handle the simulator's complex visuals and flight dynamics with minimal latency.
In defense or professional testing environments, where multiple computers or operators are involved in the simulation, our software interface is fully network-capable. This allows seamless integration of additional systems, enabling real-time collaboration between operators, instructors, and analysts across different workstations. The networked configuration can synchronize multiple computers, facilitating more advanced scenarios such as mission training, multi-role exercises, and complex flight testing, all while maintaining high fidelity and accurate data exchange across systems.
Frames:
Materials are typically laser or CNC cutted wood, plastic and aluminum materials, glued and screwed assembly. In some cases we use steel and fiber glasses.The shell or tube depended on the individual choices. And can dramatically impact the cost of the simulator.
The way we work:
We leverage the latest in 3D CAD tools for design and documentation, ensuring every component is precisely modeled before production. Our manufacturing process incorporates advanced 3D printing and laser-cutting technologies, allowing us to produce highly accurate, custom parts efficiently and with unparalleled quality. This modern approach enables us to adapt to the future of flight training, continually delivering cutting-edge simulators that meet the evolving needs of the aerospace industry.
Summary:
As the aerospace industry has rapidly evolved over the past decade with advancements like Electric Vertical Take-Off and Vertical Landing (eVTOVL) aircraft and Unmanned Aerial Vehicles (UAVs), better known as drones, the role of pilots has transformed. While many pilots now operate remotely from office environments, retaining the ability to take control at any moment, the demand for high-quality pilot training has never been greater.
Virtual Reality (VR) and Mixed Reality (MR) environments are revolutionizing pilot training, offering immersive and realistic experiences that significantly reduce the need for in-flight instruction.
The need for simulators will only increase in the future, for example, F-35 pilots complete all their training in simulators before ever flying the aircraft. Given the aircraft’s single-seat design, simulators provide the critical preparation required for pilots to operate independently without an onboard instructor.
As new generations dream of flight, and as the technologies around them continue to evolve, USAeroSim remains committed to developing cutting-edge simulators that meet these growing demands. We strive to push the boundaries of simulation technology, ensuring that both hobby and professional pilots in the future are equipped with the most realistic simulators.
As the aerospace industry has rapidly evolved over the past decade with advancements like Electric Vertical Take-Off and Vertical Landing (eVTOVL) aircraft and Unmanned Aerial Vehicles (UAVs), better known as drones, the role of pilots has transformed. While many pilots now operate remotely from office environments, retaining the ability to take control at any moment, the demand for high-quality pilot training has never been greater.
Virtual Reality (VR) and Mixed Reality (MR) environments are revolutionizing pilot training, offering immersive and realistic experiences that significantly reduce the need for in-flight instruction.
The need for simulators will only increase in the future, for example, F-35 pilots complete all their training in simulators before ever flying the aircraft. Given the aircraft’s single-seat design, simulators provide the critical preparation required for pilots to operate independently without an onboard instructor.
As new generations dream of flight, and as the technologies around them continue to evolve, USAeroSim remains committed to developing cutting-edge simulators that meet these growing demands. We strive to push the boundaries of simulation technology, ensuring that both hobby and professional pilots in the future are equipped with the most realistic simulators.
Frank Riedel
USAeroSIm
