CASE STUDY

Beyond the Headset: How Varjo Alpha Helped Entrol Maximize Their XR Simulator’s Performance

Varjo’s team of solutions engineers paid a visit to Entrol’s headquarters in Madrid, Spain, to support one of the aviation industry’s leading simulator manufacturers. With the refreshed XR-4 Series headsets, they are setting a new benchmark for immersive training.

Customer

Industry

Aviation

Category

Simulated Training

Headset

XR-4 2026 Edition

Gaia_FocalEdition_HeroFrontRight

Services

Varjo Alpha

About customer

Founded in 2005, Entrol designs and delivers certified flight simulators that meet EASA and FAA certification standards. Their extensive portfolio covers simulators from entry-level Flight and Navigation Procedures Trainers (FNPT) to advanced Full Flight Simulators (FFS) used by aviation professionals worldwide. With their in-house technology and expertise, the company supports customers throughout the simulator’s lifetime.

Entrol has already successfully deployed two mixed reality training solutions powered by Varjo headsets. The first is their Cockpit-Based MR System for pilot training, which replaces the traditional cockpit projector walls with the Varjo XR-4 Focal Edition for improved immersion.

The second solution, their MR Hoist Operator Station, targets rear-cabin training for helicopter rescue operators, featuring a fully functional hoist and a chroma key environment synchronized with the cockpit.

A Clearer View of the Skies

XR brings substantial benefits, most notably a near-360-degree field of view that allows pilots complete freedom to look around in all directions. The immersive nature of the simulation also provides improved depth perception, which makes procedures such as approaches and landings more realistic and intuitive. Additionally, the system has a significantly longer lifespan than traditional projectors, as there’s no need to replace them frequently.

“XR headsets effectively solve the biggest challenges we face with projectors, because they rely on a single display system,” says Enrique Silvela, Lead Visual Engineer at Entrol. “It provides a more immersive training environment and is ultimately better for our clients; it’s more cost-effective and much easier to maintain.”

After exploring numerous XR headsets, Entrol found that Varjo’s passthrough technology stood out as the most advanced and high-resolution solution on the market. This was essential for their ongoing work developing high-performance solutions for pilots. “The realism it delivers is unmatched, and this level of immersion is ultimately the key to improving training effectiveness. As Varjo’s headset portfolio has grown, we have been able to build increasingly advanced systems powered by their technology,” says Javier Diaz, Visual Engineer at Entrol.

Varjo XR-4 2026 Edition

refreshed Varjo XR-4 series

High-Immersion Flight with the Redesigned XR-4 Series

Entrol is integrating the refreshed Varjo XR-4 Focal Edition, purpose-built for training across domains, into its mixed reality training simulators. The newly engineered headset focuses on two critical improvements: greater comfort for long training sessions and improved visual fidelity through reoriented cameras. The headsets' redesigned headband and slimmed rear counterweight ensure stability and comfort during high-intensity pilot training.

"With the latest model, I really like the improved ergonomics. It's improved quite a bit, mostly for small movements in the cabin. It does not feel like the headset is trying to get away from me and it felt much more connected to my head," Diaz says.

Inside the device, an advanced real time eye tracking system monitors where the trainee is looking at all times throughout a session. Building on this capability, the new headset series pioneers AI-improved passthrough with gaze prediction capability to further enhance immersion and reduce system load during high-intensity simulations.  "The eye tracking has improved quite a lot and it's easier for us and for pilots to perform a more focused flight," notes Diaz.

Entrol's remarks on the 2-day workshop with Varjo Alpha

Ensuring Top-Tier Performance Where It Matters Most

Entrol’s showroom simulator—a FTD Level 3 model of the Airbus H145—still required some further optimization to operate at its full potential. In this setup, Entrol has integrated their most advanced technologies, both in terms of flight control systems and in the visual experience it can provide. The team knew it had to deliver the best possible experience, as it is the very first simulator prospective clients encounter when visiting the company’s headquarters.

“Initial internal testing revealed that the simulator wasn’t quite meeting our company’s high standards. That’s why we reached out to Varjo,“ Diaz explains.

XR solutions support

Beyond the Headset

High-end XR systems involve more than just plugging in a headset. From hardware and software integration to mission-critical reliability and security compliance, every project comes with its own set of challenges.

With Varjo Alpha, solutions engineers work alongside teams to deliver optimized XR experiences that perform in the real world. From years of working with the most advanced XR use cases, Varjo’s support and solutions teams know what’s needed to succeed. Chances are, if you’re facing an XR challenge, they’ve already solved it.

 

Discover Varjo Alpha
Varjo cockpit training

Hands-On Optimization with Varjo Alpha

The Varjo Alpha solutions engineering team responded with a two-day on-site workshop to address these challenges, bringing their expertise directly to Entrol’s simulator floor. The goal of the visit was to identify system bottlenecks and validate performance through hands-on testing with the Alpha team’s own hardware and expertise in the mix.

The first step was to evaluate the hardware setup to uncover areas for improvement. Entrol’s team had already identified some performance concerns, but Varjo’s in-depth assessment quickly pinpointed specific components, like outdated parts and compatibility limitations, that were creating the issues at hand. To clearly illustrate the core problem, the Varjo Alpha team brought along a high-performance PC for a direct comparison highlighting the gaps in the existing configuration.

Another critical focus area was cockpit lighting, which is especially important in mixed reality environments. Since the simulator is fully certified, Entrol was restricted from making permanent structural changes to the setup. To overcome this, Varjo’s team introduced a practical solution: temporary magnetic lighting fixtures that could easily attach to the cockpit interior. This fix proved to be highly effective, as it dramatically improved image quality through the headset’s passthrough cameras and helped to elevate the simulation’s overall realism and training effectiveness.

“We definitely learned a lot from the Varjo team. From the beginning, it felt very natural to work with them—they clearly have deep expertise in both Varjo's own technology and the mixed reality field in general. ”

Javier Diaz, Visual Engineer, Entrol

Entrol mixed reality flight simulator

Tailor-made help

A Technical Collaboration Built on Feedback and Results

Following the workshop’s hands-on testing and data collection, Varjo delivered a detailed technical report outlining the necessary improvements to optimize the simulator environment. Entrol has already implemented some of the Alpha team’s recommendations and has seen clear improvements in their solution as a result.

“The corrections they suggested were highly specific and tailored to our setup and operational needs,” says Diaz.  “Thanks to the outcomes of that workshop, we are now seeing significant progress in the quality and performance of our simulation system.”

In turn, the Entrol team shared feedback with Varjo on what they, as users, needed from the solution. What stood out was Varjo’s genuine receptiveness. “They listened closely, quickly acted on feedback, and began to work on improvements immediately,“ Diaz notes.

“That openness to dialogue is incredibly important to us. When a key technology provider is responsive and collaborative, it builds a strong foundation for a deeper partnership.”

Varjo XR-4

building on the simulation ecosystem

Shared Innovation Drives the Industry Forward

Looking ahead, the Entrol team sees partnerships like this as key to driving broader advancements across the simulator industry. In their view, the aviation industry grows stronger with collaboration rather than competition.

“We truly believe this type of collaboration can lead to even more comprehensive solutions and improve the entire simulation ecosystem,” Diaz says. “Ultimately, it benefits everyone involved: pilots, manufacturers, technology providers, and most importantly, it contributes to enhancing aviation safety, which is our core mission.”

Reflecting on their own experience, the team is confident in the value of the collaboration. “I would recommend Varjo’s service to other companies. In the end, the workshop was extremely valuable for us, and we genuinely believe it would be just as beneficial for other companies as well,” Diaz says.

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