Why Soft Skills Matter as Much as Technical Skills in Flight Simulator Maintenance

When most people think of a flight simulator technician or engineer, they picture someone with a soldering iron in one hand and a wiring schematic in the other, peering into the guts of a motion system or reprogramming a complex avionics interface. They picture someone whose knowledge of electronics, hydraulics, computer hardware, and specialised software borders on encyclopaedic.

It’s true – the technical mastery required to keep a Level D full flight simulator operational is immense. But there’s another, less obvious ingredient that separates a competent technician from a truly great one: soft skills.

In an industry where the pressure is high, the timelines are tight, and the stakes are directly linked to aviation safety, these human-centred skills are not “nice to have”. They genuinely are essential.

A Helicopter Flight Training Device

I’ve worked with technicians who could recite the part number of a motion actuator from memory, but who struggled to explain a fault to a customer without causing confusion or frustration. I’ve also worked with others who could not only fix the fault but also reassure the pilot, liaise with operations, and document the repair so clearly that the regulator’s eyebrows would raise in admiration. Both had technical skills. Only one had mastered the art of combining them with soft skills – and that made all the difference.

So, let's explore the soft skill areas that make all the difference.

Soft Skills in Flight Simulator Maintenance - The Heart of Every Team

If there’s one skill that underpins all others, it’s communication.

A flight simulator technician might be called upon to brief a training manager on why the visual system is down, explain a control loading issue to a pilot who has a session in ten minutes, or walk a junior technician through a complex alignment process. In each case, the audience’s technical background will be different.

Clear communication is all about translating technical complexity into terms that the listener can understand and act upon.

An AW139 Simulator Cockpit

I remember one incident early in my career where the Level D simulator I was responsible for suffered a motion system fault 30 minutes before a critical recurrent check ride. The instructor wanted to know, in plain terms, “Can I still train?” The wrong answer would have been a rambling explanation of hydraulic pump pressure thresholds. The right answer, which I learned to give later in my career would have been:

“Not safely. The motion system needs immediate maintenance. We can switch to fixed-base and you could train for part of your requirements, but we’ll have to reschedule the motion-dependent elements.”

That answer is short, clear, and operationally useful.

Communication also means listening. Too often, we think of communication as speaking, writing, or instructing. But in simulator maintenance, some of the most important information comes from listening carefully to the people who use the device. A pilot might say, “The controls felt a little heavy on rotation.” That’s not a vague complaint, it’s a clue that something in the control loading system could be out of tolerance.

Good technicians listen for these cues, ask follow-up questions, and use the answers to diagnose issues that might otherwise go unnoticed.

Problem Solving Under Pressure

When a fault appears in the middle of a training day, the clock starts ticking. The simulator is almost always booked back-to-back, instructors are under pressure to complete their required training, and pilots may have travelled halfway across the country (or the world) for their session.

Technical problem solving is the core of what we do, but doing it under pressure is a different skill altogether.

One of the most memorable examples from my own career was during a night shift in the middle of a tropical storm. A motion system fault warning popped up halfway through a type rating session. The simulator was grounded, and the next available slot for that crew would be weeks away.

A Full Flight Simulator with Hydraulic Motion

The easy route would have been to declare it unserviceable and send everyone home. But with a cool head, we diagnosed a faulty sensor in the actuator feedback loop, swapped it from our spares stock, and recalibrated the system, all in under 45 minutes. The crew got their training done, and the airline avoided a costly delay.

Our skills in this scenario weren't simply about about knowing how to troubleshoot to find which sensor to replace. Our ability to stay calm, prioritise actions, and make decisions with incomplete information – all hallmarks of strong problem-solving soft skills - were the key to achieving the desired outcome.

Teamwork and Collaboration

Flight simulator maintenance is rarely a solo endeavour.

Even the most skilled technician can’t complete a full preventive maintenance inspection, install a major hardware upgrade, or recover from a complex fault alone. We work in teams, sometimes small, sometimes spread across multiple sites and time zones.

Dismantling an old projection system

Good teamwork goes beyond simply dividing up tasks. Great simulator maintenance teams are all about understanding strengths and weaknesses, sharing knowledge openly, and supporting colleagues when they need help.

I recall working on a large-scale visual system upgrade where three technicians were responsible for dismantling the old projector mounts, while another team prepped the new high-resolution laser projection system. The project ran smoothly because each of us trusted the others to deliver, and because we communicated constantly about progress, snags, and next steps.

Without that level of cooperation, the project would have run over schedule, potentially delaying the airline’s training programme.

Adaptability in a Changing Industry

The simulator industry doesn’t stand still.

New software builds, updated flight models, upgraded visual databases, and regulatory changes are a constant. A technician who can adapt quickly, and without resistance, is worth their weight in gold.

Adaptability is also about leaning into unexpected situations. Spare parts delayed in customs, a software patch introducing an unforeseen bug, a sudden change to the training syllabus, all of these can throw a wrench into even the best-planned maintenance schedule.

During the early stages of the pandemic, for example, many simulators were mothballed for months. When training resumed, technicians had to adapt rapidly to a backlog of maintenance tasks, rusted hydraulic fittings, and unexpected system faults caused by prolonged inactivity. Those who could think on their feet and adjust priorities kept training programmes moving.

Professionalism and Customer Focus

We don’t just maintain machines, we represent our organisations.

A technician who turns up late, dresses sloppily, or dismisses a customer’s concerns will undermine confidence in the entire operation. Professionalism isn’t about formality for its own sake, it’s about trust.

Customers, whether they are airline training managers, pilots, or regulators, need to know that we take their needs seriously, that we respect the importance of their time, and that we are committed to safety above all else.

Professionalism also ties into customer focus. A good technician doesn’t just fix faults; they think about how the fix impacts the training programme. Can the session continue in a limited mode? Is there a way to reconfigure the simulator to meet the day’s training goals while the fault is addressed?

Why Soft Skills Strengthen Safety

In aviation, safety isn’t negotiable, and soft skills are directly linked to it.

Clear communication prevents misunderstandings that could lead to incorrect configurations. Strong teamwork ensures that maintenance tasks are completed and double-checked. Adaptability allows quick responses to faults that might otherwise cause unsafe conditions.

Every major aviation safety body, from the UK CAA to EASA, recognises human factors as critical to safe operations. In simulator maintenance, human factors are soft skills in action.

Developing Soft Skills Alongside Technical Skills

The good news is that soft skills can be developed.

Mentorship programmes, cross-training with other departments, and deliberate practice in customer-facing situations all help. Role-playing fault-response scenarios can improve communication under pressure. Regular debriefs after maintenance tasks can strengthen teamwork and problem-solving skills.

Companies that value and reward soft skills, not just technical output, build stronger, more resilient teams. And technicians who invest in their own soft skill development find themselves more trusted, more effective, and more in demand.

The take home message

In simulator maintenance, technical skills get the job done, but soft skills ensure it is done well, efficiently, and in a way that supports safety, teamwork, and customer trust.

A great simulator technician is not only a master of their systems, but also an effective communicator, an adaptable problem solver, a collaborative team member, and a professional representative of their organisation.

Investing in soft skills isn’t just good for career development, it’s good for the industry as a whole; and most importantly to you as a simulator operator - it's good for you bottom line.