How did Sabena technics, a specialist in aircraft maintenance and modification, move from traditional meetings and physical models to mixed reality, thereby gaining speed, agility, and precision?

Thanks to our mixed reality experts and the human-machine interface that supported them in this transformation.

XR technology has improved efficiency, eliminated certain design risks, and strengthened understanding internally and, above all, among customers.

A concrete example of industrial innovation, where technology meets expertise for measurable results.

— Aurélien Nadeau, Digital Modeling Service Manager (on the right)
— Philippe Cozilis, Digital Modeling Engineer (on the left)

The context: a critical industrial challenge

Sabena Technics faced a major challenge: quickly and accurately validating the design and ergonomics of two cockpit versions as part of an avionics renovation project. Traditional methods—lengthy meetings, 2D plans, and inflexible physical models—no longer met their clients’ requirements for responsiveness and precision.

“Before, we used to hold numerous meetings with the customer to present our studies. This left room for uncertainty and ambiguity. Physical models, which were complex and costly, did not allow for quick adjustments. Validations could take months.”

It was in this context that Sabena technics called on Immersion, an expert in XR solutions, to rethink its approach to digital modeling in aeronautics.

The solution: a hybrid approach combining mixed reality and tailored expertise

Sabena technics’ digital modeling department initiated this initiative with the goal of offering innovative approaches to simulation and collaboration around complex digital models.

Sabena Technics partnered with Immersion, a specialist in extended reality and human-machine interfaces, to deploy a customized, integrated XR (extended reality) solution tailored for the aviation industry.

It combines:

  • Technical and hands-on support: development of a custom Unity application, team training, and provision of two Varjo mixed reality headsets XR-3 headsets (for pilot and co-pilot), renowned for their exceptional precision.
  • High-fidelity digital models created from high-resolution 3D scans and 3D designs from the engineering department.
  • A simplified physical mockup of the cockpit, designed in collaboration with the furniture workshop, serving as a real-world environment for optimal immersion.

“We were looking for an open and flexible solution to leverage mixed reality with Varjo headsets. Immersion quickly understood our business challenges and provided us with support and constructive advice, focusing on understanding our needs rather than selling us closed-system solutions.”

Applications: Realistic simulation and enhanced collaboration

Through this collaboration, Sabena technics was able to use mixed reality to:

  • Simulate and test the layout of equipment in both cockpit versions with unmatched precision and the ability to make adjustments in real time.
  • Validate ergonomics across all simulated flight phases by immersing HMI experts in a realistic environment.
  • Engage all stakeholders—design offices, subcontractors, customers, pilots, authorities, and partners—in collaborative work sessions where everyone can interact naturally with the digital model.

“Mixed reality offers a collaborative experience where people see and interact with one another naturally, unlike virtual reality. Comfort and visual accuracy are essential for users to feel at ease and for meetings to be effective.”

The benefits: measurable results and process transformation

This solution, which combines mixed reality and HCI expertise, has transformed the validation process, making it faster, more collaborative, and more practical for everyone involved.

1- Time savings and flexibility
The complete validation of the design and ergonomics of both cockpits was completed in 10 months a significantly reduced timeline. Interim validations, which previously took several months, can now be completed in just a few days.

2- Reduced risks and costs
Risks are identified and addressed very early in the design phase, avoiding costly redesigns. Ambiguities are eliminated, understanding is smoother, and customer satisfaction increases.

“We can involve the client very early in our studies and quickly validate design choices.”

3. Necessary process qualification
To internally certify this digital mockup method, the complete setup PC, MR headset, and Chroma Key background was installed directly in the actual cockpit at the Sabena Technics Dinard site.

“Once again, pilots and co-pilots were able to simulate flight scenarios and checklists, alongside certification authorities and human factors experts. It was a very productive day, with no bugs or crashes, and all features were tested at the Bordeaux site.”

4. Enhanced collaboration and innovation
A wide range of stakeholders in the aviation sector—manufacturers, suppliers, and regulatory authorities—were involved.

“We’ve received very positive feedback on the use of this type of simulation.”

Sabena Technics has even discovered new applications: creating demonstration videos that showcase its expertise, which are also used for employer branding and recruitment.

Immersion’s Support Services: Recognized Expertise

As an expert in XR and HMI, Immersion played a pivotal role in this project, thanks to its ability to design immersive and collaborative experiences tailored to Sabena Technics’ industrial needs, and distinguished itself through:

  • A deep understanding of industrial and operational challenges.
  • Personalized support that combines training, consulting, and rapid skill development for teams.
  • Open and flexible solutions designed to evolve alongside Sabena technics’ needs.

“Immersion has enabled us to become fully self-sufficient with the solution. Today, we have end-to-end control over our XR environment. That’s exactly what we were looking for.”

But beyond the technical aspects, Immersion has truly acted as a partner.

“The team provided us with advice and constructive feedback—a level of support that is rare and invaluable in this type of collaboration. ”

Finally, Immersion has enabled Sabena technics to save considerable time on technology monitoring by facilitating hardware testing and performance comparisons. “Thanks to this collaboration, we were able to quickly evaluate several XR solutions and benefit from customized technology monitoring. It’s a significant time saver.”

Feedback: Satisfied Users

Feedback from users clients, pilots, internal teams, and certification authorities has confirmed the value and relevance of the solution implemented.

1- Pilots
The pilots, Sabena technics’ end customers, were able to run through their checklists and flight scenarios directly within the immersive environment.

“These sessions were not mere demonstrations, but genuine training sessions under realistic conditions. Comfort and visual accuracy were essential for them to feel fully immersed in the experience.”

2. Certification Authorities
Certification bodies such as EASA (European Union Aviation Safety Agency) and the DGA (French Directorate General of Armaments) have praised the system’s rigor and quality. “The authorities were convinced that our simulations accurately reflected the aircraft’s actual performance, which facilitated the validation process.” ”

3. Understanding and Decision-Making

“Communication has become much clearer. We can involve the client from the earliest design phases and validate design choices much more quickly.”

4. Internal Teams and Visitors
The “wow” factor remains consistent, even for the most experienced users.

“Working at actual scale in the design process makes a huge difference: it improves the perception of ergonomics and encourages constructive feedback on the design. ”

5. The impact on the employer brand
The XR solution also highlights internal innovation and attracts new talent.

“We welcome many students and visitors. These demonstrations always make an impression and showcase our expertise. Videos from the project are now used as communication tools to highlight our professions and attract new talent, particularly at events like the Paris Air Show.”

A successful collaboration that opens up new opportunities

This project has profoundly transformed Sabena technics’ digital prototyping processes. Mixed reality has now established itself as a strategic tool for accelerating validation, improving collaboration, and reducing risks from the design phase onward.

Thanks to this solution, Sabena technics has been able to:

  • Save valuable time by completing validations in a matter of hours rather than several months.
  • Strengthen collaboration among all stakeholders, from pilots to regulatory authorities.
  • Position itself as a leader in industrial innovation.

“Our collaboration with Immersion continues beyond this initial project. We are exploring new R&D developments and count on Immersion to support us. The quality of our interactions and their internal visibility make Immersion a recognized partner within our organization.”

Since this success, Sabena Technics has deployed a comprehensive XR system based on Varjo XR-3 headsets and Unity technology.

  • An immersive “Chroma Key” room, entirely covered in blue film, was designed to enable large-scale simulations.

“Avionics modification isn’t limited to the cockpit. Extending mixed reality to the entire aircraft was a logical next step. This room allows us to involve all departments wiring, integration, maintenance in a unique collaborative experience. ”

The digital modeling team has become proficient in Unity, developing its own templates and scripts to create new XR features.

“We’ve structured our development efforts and trained a Master’s student in Game Programming on our industrial projects. Today, we design our own tools and are gaining greater autonomy on every project.”

A transformative project

As Marc Audonnet, XR Products Sales Officer and Sabena technics Account Manager at Immersion, points out:

“This project marked a real cultural shift at Sabena technics. XR is no longer seen as just a technology, but as a tool fully integrated into their industrial processes.

It’s a viable solution that has made their methods more efficient and collaborative. Another result: the digital modeling team has also gained the trust of management and other departments.

And on a personal level, it was an incredible human experience. I loved supporting them as they developed their skills and advising them.”

Beyond technological innovation, this experience illustrates the success of an exemplary collaboration between people and technology.

Like Sabena Technics, take your design processes to the next level with mixed reality.

Contact us today to find out how our solutions can support you in your industrial projects by creating and orchestrating immersive, collaborative, and truly impactful work experiences.

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Credit photo: Sabena Technics