3D Printing Cuts Costs and Lead Times for F-35 Pilot Training Systems

Wraith Systems, a Texas-based manufacturer of flight simulation hardware, has scaled production of its F-35 Hands-On Throttle-and-Stick (HOTAS) desktop training system by switching to large-format photopolymer 3D printing. The company credits 3D Systems' PSLA 270 with cutting production time by more than 60 percent and reducing assembly complexity.

The HOTAS system replicates the throttle and stick controls found in the actual F-35 Lightning II cockpit. It is used by pilot training programs that need a realistic feel without the expense of a full-motion simulator. Each unit contains a stick and throttle mounted on a base, with integrated USB connectivity for consumer and professional simulation software.

Originally Wraith produced these systems in small batches using polyurethane casting combined with manual post-processing. Output hovered at 75 to 100 units per year, which matched demand when the product was primarily sold directly to enthusiasts and smaller training facilities.

That changed when larger defense and aerospace training contractors began placing volume orders. The casting process could not scale. Each cast required tooling, and every part needed extensive finishing to meet tolerances. Lead times stretched as demand grew.

The turning point was the acquisition of the 3D Systems PSLA 270. The printer's 270 mm square build plate and 180 mm height gave Wraith enough volume to print the stick and throttle as a single piece for the first time. Previously the company had split the CAD model in half to fit inside smaller Figure 4 printers, then bonded the halves together after printing.

Printing in one piece removed the seam entirely. The result is a more realistic tactile experience for trainee pilots, and a simpler assembly process for Wraith. Production time for the sticks alone dropped from six hours per unit on a Figure 4 to ten hours for a full build of six sticks on the PSLA. That is a reduction of more than 60 percent in print production time, while freeing the older machines for other parts.

The material is 3D Systems' PSLA 271, a high-rigidity photopolymer engineered for end-use parts that need dimensional stability and smooth surface finish. The choice reflects a broader trend in simulation hardware: manufacturers are moving from rapid-prototyping resins to production-grade materials as additive manufacturing becomes a volume production method rather than just a prototyping tool.

Wraith is now shipping HOTAS systems in quantities that would have been impossible under the old casting workflow. The company did not disclose specific order volumes, but described the PSLA 270 as a capacity multiplier that changed its pricing and delivery model.