Wraith Systems scales production of F-35 desktop pilot training system with AM
Before a pilot is ready to take to the air, extensive training must be carried out, much of which involves hands-on tools and simulators. For instance, pilots-in-training gain skills and knowledge by using realistic pilot training systems such as the Desktop Hands-On Throttle-and-Stick systems (HOTAS). These desktop devices give future pilots the feel of controlling an aircraft without the need for a full cockpit simulation. Texas-based Wraith Systems is one of the leading companies that designs and manufactures these pilot training tools.
Wraith Systems was founded in 2006 by veteran Jason McAlister, a pioneer of desktop HOTAS who was inspired to create the accessible training tools following his own training experience. As the founder and CEO explained: “When I did my initial pilot training in the US Marines, we were told to read certain chapters of a book and then be prepared to demonstrate that knowledge in the classroom or a simulator. This approach lacked any opportunity to refine the motor skills, the button-pushing and switch-ology required to fly a plane. The inevitable knowledge seep of what’s been read and then getting tested a couple of weeks later usually resulted in having a clipboard thrown at me by the instructor in the simulator.”
The desktop training system is simple enough: it consists of a throttle and stick based on the F-35 fighter jet mechanism that can be plugged into a computer or laptop for immersive flight simulations. Originally, the product was made in relatively small quantities using a combination of polyurethane casting and manual post-processing. “For years we were producing maybe 75-100 systems per year which equaled demand at the time,” McAlister said. “All were produced manually, with multiple parts and each needed about 20 hours of post-processing labor to complete.”
In 2023, however, the demand for the desktop HOTAS rose to about 100 units per month and the Wraith Systems team needed to find a way to scale their production quickly. Injection molding wasn’t quite viable at those production volumes and imposed limitations on the design. According to Wraith Systems, ordering a master mold for the HOTAS alone would reportedly cost hundreds of thousands of dollars. They did also consider machining the parts, but ultimately landed on 3D printing as the solution. Specifically, 3D Systems’ Figure 4 photopolymerization system.
The Wraith Systems team worked with 3D Systems’ Application Innovation Group (AIG) to develop the process. In the end, by using a combination of the Figure 4 3D printer and Figure 4 PRO-BLK 10 high-resolution resin, it found it could achieve the design, quality, and scale needed. “There are no 90 degree angles on any of these parts because they are designed to fit a human hand,” he said. “This makes 3D printing ideal for this and the post-processing time is minimal, resulting in a reduction of about 92%. The parts come out looking exactly right, we clean them, dry them and cure them and they’re ready for assembly.”
At first, Wraith Systems invested in three Figure 4 solutions. After tackling the learning curve, the company acquired three more systems in 2024 and was able to bring even more production in house. This enabled it to overcome material sourcing delays (particularly for aluminum) and bring down component costs. For instance, by consolidating the internal design of the HOTAS and replacing aluminum components with 3D printed parts, it was able to achieve a cost reduction of $13.35 per set.
At this stage, Wraith Systems was producing up to 75 desktop HOTAS sets per month on its six 3D printers, marking a productivity increase of 7.5 times and resulting in a total production cost savings of $483,735 on the last project of 813 units. However, the company still saw room for potential improvement.
In 2025, Wraith Systems acquired 3D Systems’ new PSLA 270 3D printer, whose larger build volume enabled the company to increase its production capacity as well as build quality by minimizing assembly requirements. As McAlister says: “With Figure 4 production we had to cut the stick and throttle CAD design in half because of the limited build size. In terms of assembling the electronics the two halves were quite workable, but screwing them together left a seam and the real ones (in fighters) are a single piece with no seams.” The size of the PSLA 270 enabled Wraith to print the stick and throttle as a single piece, not only simplifying assembly but also making for a more realistic simulator.
With the Figure 4 3D printers, Wraith Systems was printing six sticks per night (five hours per stick). Now, with the PSLA, it is possible to print those six sticks in a single build that takes 10 hours. “That reduces print production time by over 60% for the sticks alone and allows me to produce other parts on the Figure 4s simultaneously,” he added.
Having successfully scaled its production to meet growing demand with the help of 3D printing, Wraith Systems is now looking to greater growth. Namely, the team is looking to expand its product line into the UAV and drone markets, as well as supplying low-volume training devices for different types of fighter planes. “Really, with Figure 4 and the PSLA 270, we are now in a really strong position to expand production not just with our current production line but with spin-off products as the industry demands,” McAlister concluded.
