Many customers ask how our large USA LED aviation weather maps are made, so we recorded a video showing the full build process from start to finish.
Each map is assembled by hand in our workshop and goes through several steps before it is ready to ship.
Watch the Full Video
You can watch the full build process here:
Testing and Preparing the PCBs
Every map consists of multiple LED PCBs that are designed by us specifically for the PilotMap.
Each PCB is tested individually to make sure all LEDs work correctly.
We then install the mounting brackets using a special jig.
The brackets are 3D printed in-house and allow the boards to be aligned precisely during assembly.
Aligning and Connecting the Boards
The large USA map uses six individual PCBs.
We place them into an alignment jig, make sure everything lines up perfectly, and screw the boards together.
After that, the boards are connected using PCB connectors so the whole map works as one unit.
Full Map Test
Once everything is connected, we install the hanging cable and test the complete map using our testing devices to make sure all LEDs respond correctly.
Preparing the Printed Map
Next, we laser cut the holes for each airport in the printed map overlay.
The printed map is placed on top of the PCB, and we use specially designed anchors to secure the paper to the board.
Frame Assembly and Final Testing
After the overlay is installed, the full assembly is placed into the frame and screwed down.
The map is then tested again using real METAR data to make sure the entire system works correctly before it is packed.
Packing and Shipping
For protection, we use our bubble wrap machine to create custom padding for every map.
Each map is then packed in a box and shipped to its new home, ready to plug in and display real-time aviation weather.