Simulation & Training
- Full flight simulator displays
- Flight training device panels
- Procedure trainers
- Maintenance trainers
- Part-task trainer hardware
Form-fit-function simulator hardware that preserves cockpit fidelity while reducing cost of ownership versus flight-grade equipment.
Overview
More realistic devices. Safer pilots and travelers. Polytronix brings its expertise manufacturing flight-worthy products to the same form-fit-function simulator displays, cockpit replica panels, integrated training device hardware, simulator-grade PCB assemblies, serial-interface boards, replica cockpit pedestal and overhead structures, instructor operating station harnessing, and complete box-build simulator subsystems for full flight simulators (FFS), flight training devices (FTD), procedure trainers, maintenance trainers, and part-task trainers.
Our simulation hardware mirrors the form, fit, and function of operational platform avionics, supporting the visual fidelity, switch action, and pilot interface accuracy required for FAA, EASA, and military training authority qualification, while delivering significant cost-of-ownership advantages over flight-grade hardware.
We build simulation-grade active-matrix LCD displays, optically bonded cockpit replica displays, backlit instrument panels and bezels per MIL-DTL-7788 and QPL-7788 form factor, switch bezels and integrated control panels, multi-function display units, data entry displays, up-front control displays, engine fuel displays, horizontal situation indicators and electronic HSI, radar warning receiver and threat-warning indicator replicas, head-up display form-factor units, and complete cockpit pedestal, throttle quadrant, overhead, and circuit-breaker panel assemblies.
Devices can be discretely wired or integrated with serial interfaces including RS-232, RS-422, RS-485, and Ethernet for instructor operating station and simulator host control. From armored vehicles to submarines, maritime to power plants, and from general aviation through commercial and military fixed-wing and rotorcraft platforms, our simulated solutions equip demanding pilot, crew, and operator training programs.
Polytronix supports prototype, low-volume, and high-volume training-device production with build-to-print, design-collaboration, and full reverse-engineering programs for legacy aircraft and rotorcraft. PCB assembly, cable and harness, box build, and panel manufacturing capabilities are integrated under a single configuration-controlled workflow with AS9100D, ISO 9001, and ITAR-registered production for defense-customer training programs.
At a Glance
| Certifications | AS9100D, ISO 9001, ITAR |
|---|---|
| Program Fit | FFS, FTD, Procedure Trainers, Maintenance Trainers |
| Core Strengths | Replica Panels, Interface Boards, Trainer Harnesses |
| Typical Deliverables | Displays, Panels, Harnesses, PCBAs, Box Builds |
| Volume Range | Prototype to Production |
Simulation and Training Products and Assemblies
- Full flight simulator (FFS) cockpit displays
- Flight training device (FTD) panels and instrument replicas
- Procedure trainer and part-task trainer hardware
- Maintenance training system panels and consoles
- Flat panel trainer (FPT) touchscreen interfaces
- Cockpit replica multi-function display units (MFDUs)
- Primary flight display, EHSI, and HSI replica modules
- Data entry displays (DED) and up-front control displays (UFCD)
- Engine fuel displays (EFD) and engine indication replicas
- Radar warning receiver (RWR) and threat-warning indicator replicas
- Head-up display (HUD) form-factor units
- Switch bezels, keyboards, and integrated control panels
- Overhead panels, circuit breaker panels, and fuel control panels
- Center pedestal and throttle quadrant assemblies
- NVIS-compatible simulator displays and bezels
- Display controller, switch-matrix, and dimming-control PCBAs
- Serial-interface boards for RS-232, RS-422, RS-485, and Ethernet bridge electronics
- Simulator cable harnesses for discrete-wired and serial-bus systems
- Instructor operating station interconnect and motion-base harnessing
- Replica cockpit pedestal, overhead, and side-console structures
- Box build LRUs and rack-mount simulator-host enclosures
- Build-to-print custom simulator subsystems
- Refurbishment and OEM remanufacturing of legacy panels and bezels
Simulation and Training Capabilities
Relevant Applications
Relevant Capabilities
Standards and Compliance
IPC Workmanship Standards
- IPC-A-610 Acceptability of Electronic Assemblies (Class 2/3)
- IPC J-STD-001 Soldered Electrical and Electronic Assemblies
- IPC/WHMA-A-620 Acceptability of Cable, Wire, and Harness Assemblies (Class 2/3)
Training Device References
- MIL-DTL-7788 and QPL-7788 backlit panel form factor and lighting reference
- MIL-STD-3009 NVIS compatibility for training devices
- MIL-STD-202 test methods for electronic and electrical component parts
Additional Compliance
- ANSI/ESD S20.20 ESD-controlled production environments
- RoHS and lead-free environmental compliance options
- ITAR-controlled production where applicable
Discuss Your Simulation and Training Requirements
Share your simulator display, replica panel, interface board, harness, box build, remanufacturing, or trainer subsystem requirements. We confirm fit and provide guidance.
Quality & Compliance
Polytronix maintains active third-party registrations across three U.S. facilities and international operations. Certifications are audited annually by accredited registrars.