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Engineering work · FSTD repair & retrofit

Case studies

Selected work from our engineering team. Customer identities, serial numbers and configuration details are omitted; the technical approach is not.

Los casos de estudio técnicos y sus PDF están disponibles actualmente en inglés.
Repaired A320 simulated display unit showing stable imagery
Airbus A320 FFS · Display systems

Recovering an A320 simulated display channel

An A320 display channel showed flickering white lines and unstable imagery, and the spare Simulated Display Unit (P/N 800597) couldn't be swapped in because it had its own connector damage and degraded components. We repaired the spare at component level and used it as a known-good reference to split the video chain into testable blocks. The real fault turned out to be a failed DVI fibre-optic extender (P/N 60-977-01). The spare went back into inventory and the display path was restored without a full-unit OEM replacement.

Download full case study (PDF) ↗2.4 MB
Simura simulator-compatible illuminated pushbutton module
Airbus A320 FFS · Cockpit controls

From repair to replacement: an illuminated pushbutton redesign

Obsolete Korry-style cockpit switches were failing, and exact replacements were hard to source or uneconomical. After component-level repairs showed the dependence on unavailable internal parts, we reverse-engineered the switch, designed a new PCB, produced custom 3D-printed mechanical parts and assembled and tested the units in-house. Delivered in April 2026, the new switches were installed and operated successfully in a customer A320 full flight simulator. Units are for simulation equipment only and are not certified aircraft parts.

Download full case study (PDF) ↗0.9 MB
Contamination on internal assemblies of a B747 DU-7000 display unit
Boeing 747 FFS · Display systems

Extending the life of a B747 DU-7000 CRT display

A legacy Collins DU-7000 CRT display took progressively longer to stabilise its colour and switched intermittently to monochrome. With replacements scarce, we carried out a non-destructive, component-level repair: full disassembly, removal of heavy contamination from the high-voltage and interconnect areas, connector servicing, capacitor ESR screening and rework of age-degraded solder joints. Calibration and factory modifications were preserved, and no component was replaced without measured evidence. The display returned to service after installation-level verification.

Download full case study (PDF) ↗1.6 MB
Architecture diagram of the retrofitted B737-400 simulator network
Boeing 737 Classic FFS · Systems integration

Modernising a legacy B737-400 simulator

A legacy B737-400 full flight simulator ran on an Encore 32-series host, linked to its subsystems over DR11W parallel links, with an obsolete instructor station and a fragile QTG workflow. We kept the host and aircraft model, added a controlled interface gateway, a managed Ethernet network, a modern IOS and radio and interphone integration, and rebuilt QTG execution to be traceable and repeatable. The work ran in six staged checkpoints with a defined rollback path and was handed over with recovery procedures and validation records.

Download full case study (PDF) ↗0.2 MB

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