At kpuas.com, we don’t believe in guesswork, and we don’t design our mounting hardware around fragile plastic trim clips. We build structural, zero-tolerance mounting systems for serious flight simulation enthusiasts.
To achieve aerospace-grade fitment, every product begins in our Metrology & Studio workflow. By combining advanced blue-laser 3D scanning with parametric CAD engineering, we create perfect digital twins of cockpit components before a single prototype is ever manufactured.
Here is an inside look at how your hardware is engineered:
Step 1: Sub-Millimeter Data Acquisition
True structural support requires exact dimensions. Using the MetroX Multi-line Blue Laser Scanner, we capture the raw, real-world geometry of the flight simulation hardware. This sub-millimeter data acquisition allows us to map the precise contours, structural load points, and chassis dimensions of units like the Honeycomb Alpha and Bravo, capturing millions of data points to ensure our brackets cradle the actual body of the unit.
Step 2: High-Fidelity Mesh Fusion
Once the physical data is captured, the raw point cloud is fused into a high-fidelity 3D mesh. This digital twin serves as our foundational baseline. By engineering directly against this hyper-accurate 3D model, we completely eliminate the wobble, flex, and poor tolerances found in standard aftermarket mounts.
Step 3: Parametric CAD Engineering
With the digital twin established, the design moves into the SOLIDWORKS® Premium. Here, we engineer the actual mounting bracket. We calculate the optimal depth for our structural arms, design the integrated USB-C cable relief channels, and precisely map the tolerances for our high-torque brass inserts. Every chamfer, fillet, and mounting hole is deliberate.
Step 4: Aerospace-Grade Manufacturing
A zero-tolerance design requires premium materials. Once the CAD models are finalized, the brackets are brought into the physical world using advanced Bambu Lab manufacturing systems. Printed exclusively in high-rigidity PLA-CF (Carbon Fiber), the final product delivers maximum structural integrity, temperature resistance, and a matte, anti-reflective finish worthy of a real-world cockpit.