Imagine feeling every turn, acceleration, and jolt as if you were truly inside the cockpit of an airplane, race car, fighter jet, or spaceship. This experimental motion simulator project brings that dream to life, using powerful actuators, precision control systems, and immersive motion feedback to blur the line between reality and simulation.
The 6DOF Motion Simulator Design and Build Plans will help you save dozens or even hundreds of hours of research and planning, and avoid making expensive mistakes you are almost guaranteed to make otherwise. Most flight simulation enthusiasts trying to build a Motion Cockpit end up ordering the wrong motors or mismatched parts, only to find out the hard way that mismatched components tend to fail and burn out, leading to more overseas orders and losing money and time. Not everyone is capable of being an expert mechanical, electrical and software engineer all at once, while also being an expert 3D modeller and carpenter or welder. I designed this Stewart Hexapod-type motion platform to give me and you the best bang for the buck, and let us all enjoy an experience worthy of high-end full-motion simulators at a mere fraction of the cost.
If you’re ready for the challenge, let’s start! Buckle up—this is where engineering meets adrenaline!
After enjoying my ultra-low-budget 2DOF Motion Simulator for 3 years I decided to build a budget 6DOF Motion Simulator. The jump from a static VR cockpit to a moving motion rig was as much of an immersion leap as from flatscreen to VR, if not more. Upgrading from 2DOF to 6DOF is another giant leap, maximizing the immersion that most dedicated flight simulation enthusiasts strive for!
I set my goal: an ultra-low budget build that I can justify spending a part of my hard-earned family budget on. I spent many months figuring out the design principles, calculating the geometry, finding and matching motors, power supplies and electronics, inventing hardware and software solutions for the problems I encountered, and designing and building prototypes. I wished that someone would have a concise and clear guide on how to build it. Well, now I made one available for you to purchase.
6 Degrees of Freedom: Pitch, Roll, Yaw, Heave, Surge, Sway
Modular Design for Flight Simulation and Racing: Pendular Yoke, Joystick / HOTAS and Steering Wheel / Pedals configurations.
Cost-effective wood frame design, easily substituted by a full or partial metal contstruction if desired
6 x 250W 24V Motors
6 x 13A Motor Driver Modules
1500W 24V Power Train
3 x Arduino Uno R3 controller boards running a Custom Mod of SMC3 firmware
Original 3D-printed frictionless Hall Angle Sensors design for reliable, precise and cost-effective motor feedback
Temperature monitoring module with sound alert and matrix display
Pendular Yoke design with Hall sensors
Custom 3D-printed power control and Emergency Stop box.
Custom 3D-printed Throttle Quadrant with analog Reversers, Trim, Spoiler, Condition, Fuel and Flaps axes
Custom 3D-printed Switch Box with Gear Lever and animated lights
Custom 3D-printed MCP / GPS / Autopilot Control Box
Custom 3D-printed HOTAS Extention Panel
DIY Vibration Transducers with an integrated amp
24-page Illustrated Build Guide PDF
Full Scematics / Wiring Diagram for the Electronic Control Box
Electronics Part List (BOM) with a budget calculation, prices, source links and photos
Bill of Materials for the lumber frame, including purchase size calculations and cutting lengths
Bill of Materials for the optional Control Boxes
3D Models (Blender) for the motion simulator frame and controls
3D Models (STL, CAD) of the Motor Arms for CNC or WaterJet cutting
3D-printing Models (STL files) for all the 3D-printable parts
Custom Mod of the SMC3 Firmware with smooth start, coordinated emergency shutdown and averaging filter
Arduino code for the Temp Monitor, Throttle Quadrant, Gear Switch Box, MCP/GPS/AP box and Pendular Yoke
Custom presets for FlyPT Mover motion software
Custom MobiFlight preset for the MCP / GPS / AP box
92 build photos, documenting the project, including detailed close-ups
Reference materials for recommended parts: manuals, wiring diagrams etc.
I want to share the latest iteration of my Motion VR Cockpit simulator project: a full-motion 6DOF VR Cockpit. Upgrading from a 2DOF build posed similar challenges on a new level: commercially available motion rigs are prohibitively expensive.
Flat Screen: you are looking at a plane that you are flying. Fully disconnected.
VR: you ARE INSIDE the plane that you are flying.
2DOF Motion Simulator: you get limited motion cues that let you feel what your plane is doing
6DOF Motion Simulator + VR + Custom Controls: you ARE INSIDE and FEEL LIKE YOU’RE INSIDE the airplane. The immersion is complete!
This is what VR is meant to be! Once you try a 6DOF motion simulator, you will never go back…
It really affects the way you fly – much more like in a real airplane you will avoid sudden control movements, steep turns and hard landings (other than for testing) and try to fly smoothly, so you won’t be jerked around and shaken. This is very useful for aspiring PPL students. It gets your flying much closer to realistic instantly. The difference is between knowing you shouldn’t make sudden movements but not feeling anything when you do, and actually feeling everything you do with your controls. And a hard landing would really kick your butt hard!
This is another level of immersion. Once you complete the initial setup, you will be grinning and laughing during your first test flight, if you haven’t experienced full motion simulation before.
The budget is under $1000, which is unprecedented, as far as I know, and is 3 to 5 times smaller than most DIY builds and 8 to 10 or more times smaller than the cheapest off-the-shelf options. It’s literally about 12% of what you would pay for an off-the-shelf comparable system while getting many more features, and I don’t believe there even is one that can be customized quite this way.
Your mileage may vary, depending on what materials you already have and what you may get. Some parts, such as the motors and the gas struts, were acquired online locally, while others were ordered from Ali Express.
The package has full part lists and budget breakdowns.