The Ultimate Guide to Flight Simulator Upgrade: Projector vs. LED
For operators of Level 6 Flight Training Devices (FTDs) and specialized simulators like the CL415 Water Bomber, the Visual System is the heart of the immersion. However, many legacy simulators still rely on aging 3-channel projector systems and complex collimated displays.
If you are searching for a flight simulator upgrade, you are likely facing the same challenges as many training centers: fading brightness, poor night scenes, and skyrocketing maintenance costs.
This article explores why the industry is rapidly shifting toward Direct-View LED technology and how it solves the inherent problems of legacy projection.
The Hidden Costs of Legacy Projection Systems
Maintaining a 3-projector collimated display (like the classic 200×40 degree FOV setups) is becoming increasingly difficult.
Consumables: High-end projector bulbs are expensive and have short lifespans.
Downtime: Frequent realignment and color calibration (blending) consume valuable training hours.
The “Grey” Night: Projectors cannot produce true black. In night flying simulations, “black” is merely dark grey, which ruins the immersion and training value for night operations.
Why Upgrade to LED Simulator?
The transition to LED is not just about a “newer screen”; it represents a fundamental shift in simulation fidelity.
1. Unmatched Contrast for Night Training Unlike projectors that beam light onto a surface, LED diodes emit their own light. When a pixel is black, it is truly off. This “Infinite Contrast” is crucial for pilot training, allowing for realistic night VFR (Visual Flight Rules) and runway lighting simulation without the “light bleed” typical of projectors.
2. Reliability and Zero Maintenance For a busy training center, reliability is currency. Durway’s LED solutions are rated for 100,000+ hours. There are no bulbs to change, no mirrors to clean, and no focus drift. Once the geometry is calibrated, it stays sharp.
3. Smaller Footprint Legacy collimated systems require a massive rear projection distance and a large mirror cell structure (often adding meters to the simulator’s footprint). An LED upgrade is compact. A curved LED wall requires less physical depth, freeing up valuable facility space.
Technical Considerations for Your Upgrade
When planning your flight simulator upgrade, specific technical specs matter. At Durway, we focus on the metrics that pilots actually notice:
Pixel Pitch: For a typical cockpit viewing distance (approx. 2-3 meters), a pitch of 1.2mm to 1.5mm creates a seamless retina-display effect.
Field of View (FOV): Custom curved LED cabinets can perfectly replicate the 200° x 40° FOV required for situational awareness in aircraft like the CL415.
Frame Rate: Supporting 120Hz or higher ensures smooth motion flow during high-speed maneuvers, eliminating motion blur.
Case Study: Transforming a Level 6 FTD
[Insert a generic or specific description of a project] Imagine replacing a dim, washed-out projection canvas with a vibrant, 8K-resolution LED curve. The result is not just a better picture; it’s better pilot training. The visual cues for altitude, speed, and terrain separation become distinct and immediate.
Ready to Modernize Your Simulator?
Don’t let aging technology ground your training potential. Whether you are operating a commercial airliner sim or a specialized mission trainer, Durway provides bespoke LED visual systems tailored to your geometry.
