Engineering design
Mechanical · Electrical · Embedded · Software
SIMULATED AVIONICS · ENGINEERING & MANUFACTURING
Simulated avionics
from design and validation to manufacturing
Union Avionics develops displays, flight instruments and control panels for ground-based simulator cockpits. We handle most of the electronics, software, prototype assembly and small-batch production ourselves.
01 / DISPLAY SYSTEMS02 / FLIGHT INSTRUMENTS03 / CONTROL PANELS
PRODUCTAvionics displays
PRODUCTFlight instruments
PRODUCTControl panels
CAPABILITYEngineering & small-batch manufacturing
UNION AVIONICS / 2022
Details are not
optional extras
The panel typeface, legend dimensions, screws, fasteners and mounting relationships are all part of the product design. UA checks each of them against original-equipment references and relevant aviation-panel standards. They are not upgrades; they are the basic requirements of faithful reproduction.
Typefaces, fasteners and mounting relationships may not dominate a specification sheet, but they directly affect how the equipment looks, fits and feels once installed in the cockpit.
AVAILABLE PRODUCTF-16 SERIES / DISPLAY SYSTEM
Data Entry
Display
This F-16 Series DED keeps the original dot-matrix character style while rearranging each page for a 256 × 64 OLED. It receives simulator data through USB and does not require a graphics-card video output.
- Structure
- 6061 aluminium / 7075 aviation aluminium
- Display
- 3.12-inch OLED
- Connection
- USB data-driven
- Platforms
- DCS World / Falcon BMS
DEVELOPMENT PROGRAMS
Products now in development
Each project page shows the real prototypes, changes and tests completed so far.
01 / FLIGHT INSTRUMENT
F-16 RWR
Built around the 3.25-inch military-aircraft instrument dimensions; structure, optical filter glass and control feel are being validated.
In development →
02 / FLIGHT INSTRUMENT
Fuel Flow Indicator
OLED digital fuel-flow instrument under test for display animation and Simulator Center data connection.
In development →
03 / CONTROL PANEL
CMDS Panel
The first prototype completed illumination, VFD and screen-printing tests; the revised prototype design is ready for further validation.
In development →
MECHANICAL ASSEMBLY / STRUCTURE DEVELOPMENTENGINEERING & MANUFACTURING
From structures and electronics
to software and manufacturing.
UA handles the main structural and assembly design, circuit and PCB design, embedded firmware, Simulator Center software development, panel processing, PCBA, wiring and final assembly in-house. Keeping these disciplines within one team allows us to iterate quickly and continue refining each prototype.
Interfaces & firmware
Serial · Discrete I/O · USB · CAN bus · Firmware
Prototyping & machining
Rapid prototyping · 3D printing · CNC milling · Laser engraving
Panels & illumination
Lightplates · Type IV incandescent panels · Type V incandescent panels · Type VII LED panels · Optical matching
Markings & colour
Screen printing · Dial and pointer marking · FED-STD-595 references
Production & validation
PCBA · Internal wiring · Assembly · Power-on and interface checks
FROM DESIGN TO HARDWARE
From parts to hardware
Machining, panel work, circuit-board assembly, wiring and power-on checks all happen during the actual build.
ENGINEERING JOURNAL
Manufacturing knowledge
Readable explanations of why we choose particular materials, illumination methods, legends and displays.
PROCESS & DESIGN
Backlit panels are more than illuminated legends
See how material, coating, legends and illumination come together in an aviation-style panel.
Read article →F-16 SERIES / PRODUCT KNOWLEDGEWhy use a dedicated DED?
How a dedicated DED improves cockpit reading, and why we rebuilt the layout of every display page.
Read article →COMMUNITY & UPDATES
Follow development and
manufacturing progress
We share what has been built and what changed on the website, Discord and Facebook. For product questions, you can also email us directly.
OUR CUSTOMERS
Our customers
Once installed in a customer cockpit, dimensions, mounting and daily control feel face the test of long-term use.
F-16 SIMULATOR BUILDER
The Viper Simmer
@RainmanHSTF-16C Block 50 simulator building and operation with Falcon BMS.
CUSTOMER REVIEWI recently had Union Avionics build several F-16 panels for my simulator, and I couldn’t be more impressed with the finished product.
The level of detail, precision, and craftsmanship is outstanding. Every aspect of the panels was produced with a clear focus on accuracy and authenticity, which is extremely important when building a high-fidelity F-16 simulator.
The quality of the finished panels exceeded my expectations and they make an excellent addition to my cockpit. If you’re looking for accurately reproduced F-16 panels and appreciate attention to even the smallest details, I would highly recommend Union Avionics.
Excellent craftsmanship and a great product.
CONTACT UNION AVIONICS
Building a simulator cockpit?
Tell us what you are working on. We can discuss product information, installation and project integration by email or on Discord.