Setting up a Facility for Full Flight Simulators
- Daniel de Vries
- Jul 20
- 11 min read
Updated: 3 days ago
The Blueprint for a Successful Flight Simulator Facility: What You Need to Know
The demand for highly realistic flight training continues to grow. As aviation advances and the need for skilled pilots and operators increases, full flight simulators continue to be a central element in modern training programs. These sophisticated machines provide an immersive and effective way to prepare for real-world scenarios, all within a controlled environment.
However, housing these advanced pieces of equipment requires more than just an empty room. Creating a facility that can support a full flight simulator involves careful planning and adherence to specific technical requirements. That's where experienced partners come in. Working with a company that has a deep understanding of what it takes to build or upgrade these complex facilities, ensures they meet both operational demands and regulatory standards.
This post will give you a guide to facility requirements. We'll explore the critical aspects of design, construction, and infrastructure needed to support these high-tech training tools, helping you understand the important steps involved in bringing a flight simulator facility to life.
Why Facility Design Matters for Flight Simulators
A flight simulator is a significant investment, and its performance and longevity are directly tied to the environment it operates within. The design and construction of a simulator facility are not just about aesthetics; they are fundamental to effective training, equipment protection, and efficient operations.
Impact on Training Quality
A well-designed facility directly affects the quality and effectiveness of simulator training. This goes beyond just having enough space. Factors like sound control, lighting, and environmental stability contribute to a distraction-free and realistic training experience. When the facility supports the simulator seamlessly, instructors and trainees can focus entirely on the learning objectives, leading to consistent skill development and operational readiness. A poorly designed or constructed space can introduce issues like vibrations, temperature fluctuations, or external noise, all of which can reduce the immersion and educational value of the training session (and sometimes impact the qualification of the simulators too).
Protecting Your Investment
Full flight simulators are precision devices, containing delicate electronics, complex motion systems, and high-fidelity visual systems. Proper housing extends the life and performance of this expensive equipment. This means protecting the simulator from dust, extreme temperatures, humidity, and power irregularities. A facility that fails to provide the necessary environmental controls can lead to more frequent downtime, increased maintenance costs, and a shorter operational lifespan for the simulator itself. Thinking about the long term during the initial design phase helps safeguard this critical asset.
Operational Efficiency
Smart facility design helps with daily operations, maintenance, and future growth. Easy access for routine checks, enough space for technical teams to work, and logical layouts for power and data lines all contribute to a smoother workflow. A facility planned with efficiency in mind can reduce downtime for maintenance, simplify upgrades, and adapt more easily to new technologies or simulator models. This kind of forward-thinking approach means fewer disruptions and more available training hours, which is vital for busy airlines, aviation training centres, and defence operators.
Key Facility Requirements
Building or fitting out a facility for a full flight simulator involves addressing a range of specific technical and environmental needs. All (or most) of these requirements are provided by the simulator manufacturers themselves and are crucial for the proper functioning and regulatory compliance of the equipment.
Structural Considerations
The physical structure of the building is the starting point for any simulator facility.
Foundation
A solid, vibration-dampening foundation is essential. Full flight simulators, particularly those with heavy payload 6DOF motion platforms, generate significant forces and vibrations. The foundation must be able to absorb these movements to prevent them from affecting the building structure, nearby sensitive equipment, or even the simulator's own performance. This involves specialised concrete slabs and isolation techniques.
Ceiling Height
The critical clearance needed for the simulator's motion system is a non-negotiable requirement. Motion platforms can extend several meters vertically, so the ceiling height must accommodate the simulator at its highest point of travel, plus any necessary clearance for maintenance access above. Simulator manufacturers provide precise motion envelope specifications that must be strictly followed. This is both an issue for personnel but also equipment safety during operation.
Access and Egress
Simulator delivery, installation, and major maintenance require large door openings and clear pathways. These machines are massive and arrive in sections. The facility must have large access doors, usually overhead or roll-up, that are wide and tall enough to allow the largest component of the simulator to pass through. Additionally, there must be clear, unobstructed routes from the delivery point to the simulator bay, without sharp turns or insufficient clearances.
Environmental Control
The internal environment of the simulator bay is crucial for the equipment's health and the training experience.
Temperature and Humidity
The importance of stable environmental conditions for sensitive electronics is obviously highly important. Simulators generate heat, and their components are sensitive to temperature extremes and rapid fluctuations. A dedicated, robust HVAC (heating, ventilation, and air conditioning) system is needed to maintain a consistent temperature and controlled humidity levels within reasonably narrow tolerances, 24 hours a day, 7 days a week.
Air Quality
Filtration requirements to protect equipment are also important. Dust and airborne particles can contaminate electronic components, leading to malfunctions. High-efficiency particulate air (HEPA) filters are often recommended in the HVAC system to ensure clean air circulation within the simulator bay.
Acoustics
Sound dampening for an acoustically suitable training environment and to reduce noise pollution outside the simulator bay is vital, especially when it comes to sensitive sound qualification testing. The motion system and cooling fans of a simulator can generate considerable noise. Acoustic treatment of the walls, ceiling, and floor helps contain this noise within the bay, preventing it from disturbing other areas of the facility. It also creates a quieter, more immersive training environment for the pilots inside the simulator.
Power and Electrical Systems
A reliable and robust power supply is the lifeblood of a flight simulator. Without power, we have no simulation.
Dedicated Power Supply
A separate, stable power source is vital to effective operation of your flight simulators. Simulators have significant power demands and are sensitive to voltage and power factor fluctuations. A dedicated electrical feeder from the main power grid, separate from other facility loads, helps ensure a clean and consistent power supply, free from interference. Power factor correction devices/units are frequently used to 'clean up' the incoming power before feeding it to the simulator's main power distribution points.
Uninterruptible Power Supply (UPS)
The need for backup power to prevent data loss and ensure safe shutdown is possible is an absolute must for every training centre. These can take many forms, but typically motion systems are not backed up via UPS, only the computing systems to allow for an orderly shutdown of systems in the event of power loss. Such a controlled shutdown protects the sim's complex software and hardware from damage. For some installations, a generator backup might also be considered for extended outages.
Grounding and Surge Protection
Effective grounding and surge protection for equipment safety and longevity is a must. Proper grounding prevents electrical hazards and protects sensitive electronics from electrical noise. Surge protection systems are essential to guard against power spikes that can damage simulator components. Many training centres also include lighting protection systems to prevent surges that can occur from lightning strikes.
Cable Management
The importance of organised and protected wiring cannot be overstated. A huge network of power, data, and control cables connects the various parts of the simulator and its support systems. These cables must be neatly routed, secured, and protected from damage, making maintenance and troubleshooting much easier and quicker for future operations.
Data and Network Infrastructure
Modern flight simulators rely heavily on robust data communication.
High-Speed Connectivity
There is of course a need for robust network connections for simulator operations, updates, and diagnostics. Whilst most simulators aren't left permanently connected to the internet, when necessary, they require high-bandwidth connections for large data package downloads, software updates, and remote diagnostics by manufacturers or support teams. This often involves dedicated high-speed Ethernet lines.
Redundancy
Having backup network paths for reliability is wise. Just like with power, having redundant network connections helps ensure continuous operation, even if one connection fails. This is vital for maintaining training schedules. Fall back options like 4G/5G connectivity for internet access can help out in a dire situation where remote support is necessary.
Security
Physical and digital security for data is becoming ever more important for flight simulator operations. Protecting the simulator's software, and sensitive operational data from unauthorised access or cyber threats matters. This includes secure network configurations and controlled physical access to network infrastructure. Cyber threats to flight simulation infrastructure are becoming more prevalent than ever.
Safety and Security Features
Ensuring the safety of personnel and the security of the asset is fundamental.
Fire Suppression
There are appropriate fire suppression systems for electronics-heavy environments. Standard water sprinklers are usually not suitable for areas with such electronics. Instead, inert gas fire suppression systems (like FM-200 or clean agent systems) are often preferred, as they extinguish fires without damaging electronic equipment.
Emergency Exits
Clear and accessible routes are a must. In addition to standard building exits, the simulator bay should have clearly marked and easily accessible emergency exits, especially given the confined nature of some simulator spaces.
Access Control
Limiting entry to authorised personnel protects the equipment and ensures operational integrity. This can involve keycard systems, biometric scanners, or other security measures at entry points to the facility, the simulator bay and related computer rooms.
Monitoring Systems
Surveillance and environmental monitoring provide an extra layer of security and operational oversight. Cameras, temperature and humidity sensors, and motion detectors can provide real-time data and alerts to facility managers.
Support Areas
Beyond the simulator bay itself, several other areas are essential for efficient operation.
Briefing Room
Spaces for instructors and pilots are non-negotiable. Some simulators include off-board IOSs in an adjacent room allowing instructors to control the simulator session, monitor trainee performance, and introduce and tweak scenarios. Briefing rooms provide a space for pre-flight briefings and post-flight debriefings, where instructors can discuss performance and provide feedback.
Maintenance Workshop
Dedicated areas for repairs and adjustments are necessary. Simulators require regular maintenance and repair. A well-equipped workshop closely located to the devices allows technicians to work efficiently, with access to tools, test equipment, and spare parts.
Storage
Space for spare parts and tools is sometimes overlooked but are essential for long-term performance. Keeping recommended spare parts, specialised tooling, and technical manuals readily accessible helps reduce downtime for repairs and maintenance.
Restrooms and Break Areas
Basic amenities for staff and trainees contribute to a comfortable and productive environment. Easily accessible facilities improve the overall experience for everyone using the training centre.
Working with Simulator Manufacturers
Successfully bringing a flight simulator facility to life largely depends on close collaboration with the simulator manufacturer. Their expertise and detailed specifications are the blueprint for your facility.
Understanding Specifications
Each manufacturer has specific requirements for their simulators. These specifications go beyond general guidelines and include precise details on power consumption, heat dissipation, structural loads, environmental tolerances, and network connectivity. Failing to meet these can void warranties, lead to operational issues, or even prevent regulatory qualification. Our experience allows us to interpret and apply these specifications accurately.
Early Engagement
Bringing in experts early in the planning process to align with manufacturer guidelines yields significant benefits. Engaging with both the simulator manufacturer and facility design experts from the very beginning helps avoid costly mistakes and redesigns later on. This early collaboration ensures that the facility's design is fully integrated with the simulator's needs.
Customisation vs. Standard Designs
Simulator facilities can be tailored while still meeting core requirements. While manufacturers provide strict technical specifications for the simulator's immediate operating environment, there is often room for customisation in the overall facility layout and aesthetic. A well-designed facility can reflect your brand and operational style while still providing the essential technical support for the simulator. Our team can help you strike this balance effectively.
Why Partnering with Experts Makes a Difference
The complexity of flight simulator facility projects makes expert partnership not just beneficial, but often essential. We offer complete support, ensuring your project meets every requirement and your flight simulators achieve that Ready For Training milestone.
Cost Savings
Proper planning avoids expensive rework and delays. Mistakes in design or construction can lead to significant additional costs and push back project timelines. Our experience helps identify potential issues early, streamlining the process and keeping your budget on track. We help you make informed decisions that save money in the long run.
Regulatory Compliance
Meeting aviation authority standards (e.g., EASA, FAA) is non-negotiable. Flight simulator facilities must support strict regulatory standards to ensure the simulators within them can achieve qualification for training. We stay up-to-date with the latest compliance requirements, ensuring that your facility is designed and built to pass all necessary inspections and receive accreditation from relevant aviation authorities. This prevents delays and allows you to begin training as quickly as possible.
Faster Setup
Getting your facility operational more quickly is a key benefit of working with experts. Our project management and technical knowledge accelerate the planning, design, and construction phases. We anticipate challenges and provide solutions, allowing for a smoother, more efficient setup process, meaning your simulators can be ready for training sooner.
Long-Term Reliability
Ensuring your simulator operates smoothly for years is a core goal of every flight training centre; after all, these assets need to operate for decades. A facility built to precise standards, with proper environmental controls and robust infrastructure, reduces the risk of equipment issues and extends the operational life of your valuable simulators. We focus on durability and performance, making sure your investment continues to deliver.
Focus on Your Core Business
By partnering with experts to manage the facility details, operators can stay focused on training. Setting up a simulator facility is a specialised task that can divert valuable resources and attention from the primary mission. When you partner with us, you can trust that the facility aspects are being managed by experts, allowing you to dedicate your efforts to what you do best: providing world-class flight training or operating critical defence assets.
Summing Up
Creating a facility for a full flight simulator is a significant undertaking, requiring precise planning and attention to detail. From the structural foundation to the intricate electrical and data systems, every aspect must be considered to ensure the simulator operates effectively, reliably, and safely. A well-designed facility not only protects your investment but also enhances the quality and efficiency of your flight training programs.
We specialise in supporting complex projects. We provide engineering and maintenance services, complete with upgrades and regulatory compliance assistance, for flight simulators and their associated facilities. Whether you are an airline, an independent training centre, or a defence operator, we are here to help you navigate the requirements for building or fitting out your simulator facility.
Don't let the technical demands overwhelm your project. Contact us to discuss your flight simulator facility needs. We're ready to partner with you, offering our expertise to help you build a fit-for-purpose training environment that meets all technical specifications and operational needs. Let us help you ensure your flight simulation capabilities are safe and effective.
Q&A
How much does it cost to set up a flight simulator centre?
A new facility can be expected to cost in the region of AUD $20 million to $30 million for a facility that can house up to four (4) level D full flight simulators. This is the cost of the facility and fit-out only, it does not include the costs of the flight simulators themselves.
When it comes to the construction and fit-out of a new facility designed to house full flight simulators, the costs vary depending on the number of simulator bays required. Larger training centres with more bays (4+) offer greater economies of scale, with smaller single or dual bay centres having a higher effective 'per bay' cost.
How much space is needed for full flight simulator?
Each training device manufacturer will have their own requirements specific to the devices that they provide to their customers. However, it is generally accepted that for a single simulator bay operating a standard level D full flight simulator with a standard motion envelope, the bay will need to measure around a minimum of 12.5m x 20m x 20m (HxWxD). This is only for the simulator device itself, not the required accompanying computer room and other important elements required to operate a full flight simulator.
How much does a full motion flight simulator cost?
While a typical level D full flight simulator can cost anywhere between USD $12 million and $20 million; this number can vary greatly depending on the aircraft being simulated and the availability of existing high fidelity flight models.
Who makes full flight simulators?
There are a significant number of flight simulator manufacturers in the industry today. Some notable training device manufacturers include:
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