FLIGHT SIMULATOR SHELL

Reimagining the CAE Flight Simulator Shell for Maximum Efficiency

CAE IDEATION

When CAE, a global leader in simulation technologies, challenged us to design a flight simulator enclosure under strict budget constraints, we delivered a disruptive industrial design solution that redefined cost-efficiency and modular engineering.

Project Objectives

  • Design a complete enclosure for a flight simulator within a tooling budget of under $25,000 CAD
  • Optimize for ease of assembly, transportation, and manufacturing
  • Maintain CAE’s brand identity and aesthetic standards
  • Reduce overall assembly time, labour costs, and production complexity
Outcomes & Results
  • Zero tooling required: Enclosure designed entirely without traditional tooling processes
  • Assembly time reduced by over 80%: From 8 days down to just 1.5 days
  • Streamlined transport: Optimized weight and crate dimensions for shipping
  • Smaller install crew: Reduced from 7 to 2 people, lowering labour and travel expenses
Continue Exploring Our Work
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