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Showroom Two and 1/2 years to a working 6DOF Hexapod Flight Simulator

Discussion in 'DIY Motion Simulator Projects' started by Edward B Gilbert, Apr 14, 2023.

  1. Edward B Gilbert

    Edward B Gilbert Inventor, programmer, and CNC machinist Gold Contributor

    Joined:
    Nov 22, 2018
    Messages:
    11
    Occupation:
    CNC Operator, Inventor, programmer, and nerd!
    Location:
    USA
    Balance:
    237Coins
    Ratings:
    +4 / 0 / -0
    My Motion Simulator:
    6DOF
    I wanted to build a motion simulator two and a half years ago. Starting this project, I didn't know much about motion simulators, and the only one I had ever seen was in videos or blogs like this.
    Before diving into this build, I would like to introduce myself. I am Edward, a self-taught mechanical engineer; I run a moderately successful CNC fabrication shop in Orlando, FL. I am a decent designer and fabricator, so I had a slight advantage over most hobbies. I'm not bragging; I am just setting the stage to be able to break down how I went about all of this and how I was able to do many of the things involved.
    I have estimated that I have approximately 3,000 hours of my own time and about 200 hrs that I have paid my workers for this project. Yesterday, after months of programming and frustration, it worked perfectly, and I am satisfied with the build. I am calling this Simulator the MSV3 (Motion Simulator Version 3).

    The Simulator Idea
    I have been asked where the idea to build this came from, which is pretty interesting. I'm one of those people who can program, design, weld, paint, run CNC machines, and works with Electronics. I have probably the worst possible case of ADHD. People I work with call me the "Mad Scientist".
    I had never created a single project that was kind of a resume of all the things I could do wrapped up into one project, and during a phone conversation, my Aunt Velda suggested that I create something that was.
    I was thinking of animatronics or a robot. Then I remembered that when I was in my late 20s, I'm 55 now, I was training to be a pilot, and during a solo flight, I had a terrifying landing where a bounced all over the runway and almost put the plane on its side. Ironically, this was in the town where my Aunt lives now.
    I thought that a flight simulator would be the perfect project. I incorporated programming, engineering, electronics, motion control systems, and all the things I can do in one project, and in the end, I can create a useful tool that might have prevented the event that happened twenty years ago that ended my ambitions of becoming a pilot. And so it began.

    The Three Designs
    What I had in mind was a very sophisticated simulator that looked and felt commercial and not so much like a garage build hobby project, not that I have anything against hobby projects; in fact, I encourage them!

    Below is an video of what the simulator looks like today, and I have to say, I am happy with the look and the total outcome, but two previous builds were stripped down to nothing and scrapped.


    I will add more to this thread later, please post any questions you have about the design and I will gladly answer them.
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