When the team at Airliners Live set out to build a full-scale replica cockpit for their YouTube channel, the aim was to create a solid, realistic structure capable of supporting a home flight simulator setup.
The project comprised of several elements, the digital cockpit design files, specialist simulator hardware, and laser-cut MDF structural panels.
As a UK-based laser cutting specialist, we were asked to manufacture the MDF components used in the project, producing the parts that form the structural shell of the cockpit.
The cockpit structure was cut using digital files created by The Sim Guy, whose cockpit plans are made available to the flight simulation community through his Patreon platform.
Photo credit: The Sim Guy
These plans allow flight simulator enthusiasts to download the files required to construct their own DIY Airbus A320 cockpit structure.
The cockpit hardware installed in the build was supplied by Wing CTRL - formerly Wing Wing - whose flight simulator components replicate the layout and functionality of a real aircraft flight deck.
Working from the supplied CAD files, we manufactured the laser-cut MDF cockpit panels that form the structural framework of the simulator.
The components included:
MDF was selected as the structural material for several reasons.
Firstly, it offers excellent dimensional stability. Some simulator components, particularly items such as the throttle, require a solid mounting surface to withstand the movement that occurs when using this equipment.
Photo credit: Chris Gomersall
Secondly, laser cutting MDF produces smooth edges, and creates consistent panel geometry. This makes it well suited to projects such as this where accuracy is essential for successful assembly.
The finished components were supplied flat, and ready for assembly.
To make the build process as straightforward as possible, each part was clearly marked during production so that Martin & Andy (Airliners Live) could easily identify the position of each component within the structure.
Photo credit: Laser Cutting Services
A printed assembly plan accompanied the parts, showing each numbered component and its location within the cockpit structure.
As with most laser-cut MDF parts, the cut edges may have a slight darkening caused by the laser cutting process. This is normal and simply a result of the laser interacting with the material. The surface residue can easily be wiped clean before painting or finishing the panels.
During assembly, Martin & Andy identified a few areas where minor adjustments were needed to ensure full compatibility with their specific simulator equipment.
These small modifications were made by hand during the build to ensure the correct fit for the hardware being installed.
The laser-cut components we supplied formed the structural framework of the cockpit. Decorative finishing elements, such as blanking panels and upholstered sections, were produced separately during the build process.
Photo credit: Chris Gomersall
One of the most fascinating aspects of the build was seeing a full-scale 3D model come to life from a simple 2D design.
The finished cockpit now forms the structural base for the Airliners Live simulator setup, housing the flight controls, instrument panels, and displays needed to create a highly realistic flight simulation environment.
We were pleased to support the manufacture of the structural components used in the project and to see the cockpit structure become part of a fully operational simulator.
After the cockpit build videos were released, we received a number of enquiries from Airliners Live viewers asking about the laser-cut MDF cockpit components used in the build and whether similar parts could be supplied for their own simulator projects.
This reflects the growing popularity of home flight simulators and the increasing number of enthusiasts building their own cockpit environments.
The answer is a resounding yes.
Customers interested in producing the same cockpit structure simply need to purchase the official cutting files from The Sim Guy, and our team can then manufacture the laser-cut components from those files.
While the full Airliners Live dual-seat cockpit is an impressive build, many enthusiasts do not have the space required for a complete cockpit installation.
For this reason, smaller configurations can also be produced, such as single-seat cockpit structures. Components can also be manufactured depending on the customer's setup and the equipment they intend to install.
Projects like this raise an interesting question - why do people choose to build their own cockpit simulators?
For many, it is about creating a highly immersive hobby environment. For others, a simulator can support pilot training, familiarisation with cockpit layouts, or practice procedures outside of the aircraft itself.
The same approach could also be applied to other simulation environments, including racing simulators, other aircraft cockpit builds, or specialist training setups.
At Laser Cutting Services, we are more than happy to assist with the laser cutting of any possible simulation builds. If you have the files, we can cut them. Please get in touch (link to contact us form) with our team for a quotation.
Projects like the Airliners Live cockpit highlight how designers, simulator hardware manufacturers, content creators, and specialist manufacturers such as ourselves can work together to bring complex builds like this to life.
