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Flight simulator repository for my Highways project

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Highway-FlightSim

Flight simulator repository for my Highways project

YouTube video demo link

https://youtu.be/Q90917BsKVE

Project Description

This is a piece of hardware that can be used in a flight simulator. In particular, it is the Flight Control Unit (FCU), otherwise known as the autopilot. I tried my best to make its design mimic that of the Airbus A320. This project can be plugged into a computer and communicate with Microsoft Flight Simulator with the help of Mobiflight, a software which helps translate hardware inputs to Microsoft Flight Simulator. Users can configure the aircraft's FCU in the simulator by interacting with their physical counterparts, providing a very accurate simulation.

The project was simple overall but maximising reallism (finding accurate buttons with LEDs, if not having to 3D print contraptions of your own) was very difficult. In which case, the footprints I chose were a balance between the two.

The way it works is simple:

  1. Hardware input, Arduino send signal to computer
  2. Mobiflight translate input according to programed instructions
  3. MSFS receives signal and acts.

... or the other way around

  1. MSFS sends out signal
  2. Mobiflight translates MSFS signal and sends to Arduino according to programed instrictions.
  3. Arduino tell components what to do

Why I built it

Oh boy there were a lot of reasons why I built it

1. My school club

I run an aviation club at school currently and the main attraction is the flight simulator. Currently, it is a humble stick and throttle setup. Over the summer, I aim to expand this flight simulator by adding modular components piece by piece. This will be useful for my club and people will enjoy playing around with it more. Imagine how cool it would be to have a full, professional-looking simulator!

2. Flight sim market is overpriced

Many flight simulation hardware are insanely overpriced. For example, this one only took me about 50 USD to make. However, many on-market alternatives (although slightly more realistic) cost above 100 USD. Given that I'm broke, expanding the flight simulator by purchasing even second-handed hardware is not a sustainable solution.

3. I like aviation!

Having physical controls over the flight simulator is much better than using a mouse to set the autopilot in-game. This project will boost my experience overall.

Pictures of my project

Completed picture!!! yay!

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It in action

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Full 3D model

Full 3D model, with electronics included. Please note that some electronics I'm using do not have exact models on the 3D models website, so the colour may be off. Certain parts where things seem to overlap with eachother is also sometimes okay because some parts (nuts) can be moved during installation.

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Picture of my STEP file, all components have been laid out in printable form

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Wiring schematic

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BOM

Note: Some parts have cheaper alternatives, but the parts I selected ensured that I knew the exact dimension for 3D printing the panel (Aliexpress sellers don't often include dimensions, but I saw another person's tutorial with dimensions of certain parts so I used the exact same parts as they did to referencing their panel dimensions), and saves the need to 3D print because the resemble irl cockpit designs.

Platform Description Price per listed lot # of parts per listed lot Lots purchased Final price (CAD) Final price (USD) Already owned? Comments Link
Aliexpress Small black tactile push buttons 7.14 6 1 7.14 5.20 No https://www.aliexpress.com/item/1005008633676197.html?spm=a2g0o.detail.pcDetailTopMoreOtherSeller.11.1d88q9EYq9EYiC&gps-id=pcDetailTopMoreOtherSeller&scm=1007.40196.439370.0&scm_id=1007.40196.439370.0&scm-url=1007.40196.439370.0&pvid=1911638d-ebef-442b-bd88-88c9473bad53&_t=gps-id:pcDetailTopMoreOtherSeller,scm-url:1007.40196.439370.0,pvid:1911638d-ebef-442b-bd88-88c9473bad53,tpp_buckets:668%232846%238109%231935&pdp_ext_f=%7B%22order%22%3A%22128%22%2C%22eval%22%3A%221%22%2C%22sceneId%22%3A%2230050%22%7D&pdp_npi=4%40dis%21CAD%2114.26%217.13%21%21%2173.22%2136.61%21%402101d9ee17510557948311595e3aa5%2112000046034383569%21rec%21CA%216006689702%21XZ&utparam-url=scene%3ApcDetailTopMoreOtherSeller%7Cquery_from%3AilTopMoreOtherSeller%7Cquery_from%3A
Amazon Rotary encoder with PCB imbed 13.98 5 1 13.98 10.18 No https://www.amazon.ca/dp/B0D85XZM71/ref=sspa_dk_detail_2?psc=1&pd_rd_i=B0D85XZM71&pd_rd_w=YxwHO&content-id=amzn1.sym.516c2169-755e-413a-a38a-68230f4ab66f&pf_rd_p=516c2169-755e-413a-a38a-68230f4ab66f&pf_rd_r=419W9PB4RDM0A0HZEQHD&pd_rd_wg=U50yP&pd_rd_r=4b2d9c76-571d-42a3-8098-36e2cc89cfe8&sp_csd=d2lkZ2V0TmFtZT1zcF9kZXRhaWw_csd=d2lkZ2V0TmFtZT1zcF9kZXRhaWw
AliExpress 6-Digit TM1637 7 segment display (white) 4.19 1 1 4.19 3.05 No https://www.aliexpress.com/item/1005002060120661.html?spm=a2g0o.detail.0.0.4dafKiXyKiXyJL&productId=1005002060120661&pdp_ext_f=%7B%22tabScene%22%3A%22retail%22%2C%22sku_id%22%3A12000018594824539%2C%22origProductId%22%3A%221005002060120661%22%7D&1%22%7D&
AliExpress KD2-21 Push button with LED 10.45 10 1 10.45 7.61 No https://www.aliexpress.com/item/1005004977805714.html?spm=a2g0o.imagesearchproductlist.main.1.3111tK3ztK3zkp&algo_pvid=e40e3c0c-d635-4a86-9a2f-5bc30757e421&algo_exp_id=e40e3c0c-d635-4a86-9a2f-5bc30757e421&pdp_ext_f=%7B%22order%22%3A%22107%22%7D&pdp_npi=4%40dis%21CAD%2110.48%219.68%21%21%217.48%216.91%21%402101c5bf17505638932773575e23e6%2112000031434945632%21sea%21CA%216006689702%21X&curPageLogUid=1ifIhf84fDKW&utparam-url=scene%3Aimage_search%7Cquery_from%3Apc_web_image_searchom%3Apc_web_image_search
AliExpress 4-Digit TM1637 7 segment display (white) 2.75 1 4 11 8.01 No https://www.aliexpress.com/item/1005001570737985.html?spm=a2g0o.detail.pcDetailTopMoreOtherSeller.11.4767sZSmsZSmda&gps-id=pcDetailTopMoreOtherSeller&scm=1007.40196.439370.0&scm_id=1007.40196.439370.0&scm-url=1007.40196.439370.0&pvid=a1f1bdab-51b2-425d-ae28-311baab0dce2&_t=gps-id:pcDetailTopMoreOtherSeller,scm-url:1007.40196.439370.0,pvid:a1f1bdab-51b2-425d-ae28-311baab0dce2,tpp_buckets:668%232846%238109%231935&pdp_ext_f=%7B%22order%22%3A%22209%22%2C%22eval%22%3A%221%22%2C%22sceneId%22%3A%2230050%22%7D&pdp_npi=4%40dis%21CAD%212.53%212.53%21%21%211.80%211.80%21%402101ef7017508169963666258e5125%2112000016631629945%21rec%21CA%216006689702%21X&utparam-url=scene%3ApcDetailTopMoreOtherSeller%7Cquery_from%3AilTopMoreOtherSeller%7Cquery_from%3A
Amazon Generic Atmega 2560 board 27.65 1 1 27.65 20.13 Yes? (see comments) bought for testing if the software is compatiable with the board because it had very strict board restrictions. I didn't want to design it all and then find out that I have to switch boards and redesign the schematics. If possible I'd like the get reimbursed for it but if not that's okay https://www.amazon.ca/EC-Buying-Development-ATMEGA2560-Compatible/dp/B0BXDNF6Z6/ref=sr_1_4?crid=2KRISZ44S1LQS&dib=eyJ2IjoiMSJ9.HlS9NhZvYgKG2LgAIQvHCpi2QQj4hvq4QpQzcAJcgULXXRdv0IsiS2lFrkHZXeriiB5cikc27MNVtFMzVuFAEYVlTdthm4EWw0zXZudxM5cyKZKN3BPlkb04p363cTNgNQ-F4LQ1aqVSWrKNmx5lNLiQPUCpXqo_me174sfaNaFuLF_a19OMfCVVFL2CAzf8r1ueRcKyj1d917PSR1T7bDwDCZA678f9Fs4D8Mr2teFVovXQShleueVEm5peSIapHkaqu9WT9N08JndLxvjBB8aMePTvVA3bQu5wYEkgSmw.r7eoEA0w2Bi4v7uVYEPfFBq12rpQmaNpk3s5gKS_qNc&dib_tag=se&keywords=EC+buying+atmega+2560&qid=1751071493&sprefix=ec+buying+atmega+2560%2Caps%2C122&sr=8-40%2Caps%2C122&sr=8-4
Total (CAD, USD): 46.76 34.04
Including Arduino 74.41 54.17

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