F-16 Flight Stick
3D Scanning & Reverse Engineering for Simulation ReproductionAEROSPACE & DEFENSE
THE PROBLEM
A defense simulation developer required an exact dimensional replica of an F-16 flight control stick for use in a high-accuracy simulation system.
The customer possessed the physical component but had no available CAD data, legacy drawings, or manufacturing documentation. To produce a functional reproduction, they needed a fully parametric CAD model that captured the geometry precisely—down to every contour, switch pocket, and ergonomic curve.
The customer shipped the original F-16 flight stick to NeoMetrix Technologies for a complete digital reconstruction.
TRADITIONAL METHOD
Traditional processes would have required:
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Manual measurement with calipers or CMM probing
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Hand-built 3D models based on approximated geometry
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Lengthy reverse engineering cycles
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High probability of tolerance stack-ups, shape deviations, and “best guess” modeling
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Limited ability to replicate organic surfaces and ergonomic hand grips
This approach often results in inaccurate reproduction, requiring iterative redesign, retooling, and costly prototyping—especially with aerospace controls where even subtle shape variations impact user feel and simulator realism.
NEOMETRIX SOLUTION
NeoMetrix leveraged the Creaform HandySCAN BLACK Elite, a metrology-grade handheld laser scanner, to capture the full geometry of the F-16 stick at high accuracy.
Scanning Details
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Scanner: Creaform HandySCAN BLACK Elite
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Accuracy: Up to 0.0009 in (0.025 mm)
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Resolution: 0.025 mm – 0.05 mm (optimized for fine ergonomic detail)
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Output: Complete watertight STL mesh with full surface fidelity
The scan data was then processed through Geomagic Design X, the industry-leading reverse engineering platform.
Reverse Engineering Details
Using Design X, our engineers created:
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A full parametric CAD model reconstructing all surfaces
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Exact ergonomic contour matching
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Feature-based geometry including trigger housings, switch bays, fastening holes, and mounting interfaces
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A reconstruction workflow blending NURBS surfaces + solid features
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Fully editable feature tree for future manufacturing adjustments
- 3D Model Time:
Get ahead of the game with real-time visuzalization and accelerated mesh processing.
Scan Time: Under 10 Minutes
3D Model Time: Hours
NEOMETRIX ADVANTAGE
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Metrology-grade precision for aerospace-level replication
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Ability to digitize complex organic & ergonomic surfaces impossible to measure manually
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A fully parametric CAD file, not just a mesh
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End-to-end workflow: inbound shipping ➝ scanning ➝ Design X CAD ➝ final deliverables
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Faster turnaround versus traditional modeling
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Zero guesswork—100% true-to-original dimensions
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Perfect for simulation, training devices, tooling, and heritage part reproduction
RESULT
The client received a high-fidelity, dimensionally accurate CAD model of the F-16 flight stick, enabling exact reproduction for simulation hardware. The geometry matched the original within microns, ensuring authentic ergonomics and plug-and-play integration with their development pipeline.
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