BAE Systems needed to modernise simulator avionics for the Typhoon fighter jet – fast. We designed and manufactured precision interface panels in 3 months, enabling 13 engineering teams to advance software development immediately. Hardware built to support the programme through to 2030.
The Challenge
BAE Systems had an ambitious goal: rapidly modernise simulator avionics equipment for the Typhoon fighter jet programme. With internal resource constraints and pace a priority, they made a deliberate decision – to look locally. They wanted a trusted partner on their doorstep who could move fast, think practically, and deliver hardware their teams could get straight to work with.
That search led them to npd Studio in Preston.
What We Did
npd designed and manufactured 7’’ high-integrity panels – critical interface systems providing key flight data to pilots during development and testing of the Typhoon. These are not off-the-shelf solutions. They are precision-engineered components built to perform in one of the most demanding environments in aerospace and enable the software development teams to rapidly progress the testing of key equipment.
The solution combined commercial off-the-shelf components (COTS) with bespoke PCBs designed and manufactured by our team, sourced through our proven local supply network to keep lead times short and quality uncompromised. In 2025 we significantly increased our quantity of 3D printers, allowing us to quickly print, test and iterate on the mechanical design of the enclosure.
We invested deliberately in our security and IT infrastructure to ensure we could deliver a project of this nature securely and in full compliance with the requirements of working at this level. Throughout delivery, we applied our rapid product development approach: prototyping daily, keeping the end user central to every decision, and working at pace. Weekly face-to-face sessions meant every meeting delivered updated prototypes incorporating the latest design changes.
The Result
Delivery
- 3 months from brief to delivery – compressing what would typically take 18 months
- 13 BAE Systems engineering teams enabled to advance software development rapidly
- Hardware platform designed to support BAE Systems programmes through to 2030
Strategic Impact
- The Typhoon supports 6,000 jobs in Lancashire and 20,000 across the UK
- npd’s contribution to keeping this platform competitive is a direct contribution to the region’s strategic economic importance
- npd has secured a dedicated design studio at BAE Systems’ Warton facility – a clear signal of the partnership’s long-term strategic value
In Their Words
“At BAE Systems, we had the emergent requirement to rapidly modernise a piece of simulator avionics equipment, but internal resource constraints led us to outsourcing. We restricted our search to local businesses, knowing that a national option was unlikely to deliver a successful outcome. With that in mind, we took the chance with npd in Preston, right on our doorstep. npd exceeded all expectations delivering a fast, cost-effective and high-quality solution. Daily back-and-forth communication enabled a rapid pace of change, while npd’s innovation pushed the design beyond what we had originally envisioned. Our weekly face-to-face sessions further accelerated progress, with each meeting delivering updated prototypes that incorporated the latest design changes — demonstrating npd’s impressive agility. This collaboration was a shared learning experience and highlighted the value of partnering with a skilled local business like npd.”
Robbie Watkinson | BAE Systems Air | Typhoon Product Strategy | Systems Engineer
What This Means
Working in defence demands more than good design. It demands security credentials, compliance awareness, and a supply chain you can trust. We’ve built that capability deliberately – because the products we work on have to work, and the people relying on them need to know they will.
We’re proud members of the Northwest Regional Defence and Security Cluster, and we continue to invest in the accreditations and infrastructure that allow us to operate at this level.
What’s Next
With the high-integrity panels signed off we’re now continuing to work with their teams to rapidly develop and deploy new emerging technologies.
