CASE STUDY

Reiser and the Newly Refreshed Varjo XR-4 Series Bring Certified Mixed Reality to Professional Flight Training

Driven by customer demand for more accessible, high-fidelity training, German flight simulation powerhouse Reiser is integrating mixed reality into its simulator portfolio. Their newly pre-qualified H145 D3 MR simulator marks a significant milestone for the industry as one of the first times XR has been formally recognized by an aviation authority. 

Customer

Industry

Aviation

Category

Simulated Training

Headset

Varjo XR-4

XR-4-2026-front-right

From Family Workshop to a Global Leader

Reiser Simulation and Training GmbH is a family-owned company based south of Munich, Germany, specializing in the development, manufacturing, and support of high-fidelity simulation training devices for both civil and military aviation operators. Founded over thirty years ago, Reiser has grown from a company for components out of passion for aviation technology into a global provider of advanced Full-Flight Simulators (FFS), Flight Training Devices (FTD), and customized training solutions.

 

Reiser mixed reality simulator

Headset-Based Training Proving its Potential

According to Reiser’s technical development team, mixed reality first appeared on their radar years ago with the earliest prototype devices, and they could already then sense its long-term potential. As the technology matured, its performance became strong enough to realistically support aviation training. Reiser’s Chief Technology Officer, Martin Keil notes that the key breakthrough came when video pass-through camera quality advanced to the point where pilots could clearly read the full instrument panel and overhead helicopter controls while still seeing their own hands and body naturally within the scene. 

“That was really the decisive step forward from our perspective. It was a major leap in capability and deployment potential for real-world flight training.” 

Reiser began integrating mixed reality into its simulators in 2018, initially to support hoist-operator training in the rear cabin. Since then, the technology’s role quickly broadened into flight training and more advanced use cases. The team remembers the setup of their first mixed reality simulators as a highly positive and collaborative experience.

“Working with Varjo’s team to get our first mixed reality simulators up and running was a magnificent experience. We had an open and collaborative exchange within the team: everyone was approachable, straightforward, and fully focused on achieving results and driving progress,” says Keil.

See the certified simulator in action and hear remarks from the Reiser team

Achieving One of Aviation’s Toughest Certifications

With mixed reality now fully integrated in Reiser’s select training solutions, the technology has matured to a point where it can be formally recognized and validated by aviation authorities. The company recently announced the pre-qualification of its REISER H145 D3 Mixed-Reality Helicopter Simulator by the German Federal Aviation Office (LBA). This pre-qualification confirms that the simulator meets some of the most demanding regulatory standards in aviation and marks a major milestone for both Reiser and the broader training industry.

“I believe this is a major step forward for the industry. I'm tempted to even call it a game changer. From now on, training devices may look much different from what they did before,” Keil says.

Qualification in Germany carries particular weight, as the LBA is known for its stringent requirements; achieving approval there signals global readiness and reduces certification risk for international customers. It also streamlines development, production, and troubleshooting, which enables Reiser to deliver higher-quality training devices with greater efficiency.

the XR H145 D3 Simulator

A Flexible Simulator Designed for Realistic Crew Training

Reiser’s LBA pre-qualified simulator is built around two core components: a simulator docking station that generates all external views and environmental visuals, and a high-fidelity, fully replicated Airbus H145 cockpit with complete instrumentation and an accurate flight model. The setup also includes a green screen area where the virtual environment is blended with the physical cockpit using a chroma-key technique.

A standout feature of the simulator is its ability to train both pilot and co-pilot side by side, enabling true mixed crew coordination and resource management training. Giving crews the ability to train together in a compact, high-fidelity environment significantly increases training availability and ultimately contributes to safer operations.

“Doing this in mixed reality is particularly significant. Until now, such joint crew training was only possible on very large and complex training devices. With the new technology, we can achieve the same level of realism in much smaller, more flexible systems,” Keil explains.

 

Varjo XR-4
 

refreshed Varjo xr-4 series

Next-Generation Optics and Ergonomics with the New XR-4 Series

According to Keil, the role of the Varjo XR-4 headset within their simulator setup is crucial. “It serves as the key enabler that allows the simulator to deliver highest fidelity training while maintaining a compact form factor,” he explains.

Reiser is now integrating the newly refreshed Varjo XR-4 headsets into their systems. Optimized specifically for cockpit trainers, the new XR-4 Series introduces features such as redesigned ergonomics and an optional chin strap to ensure stability during dynamic exercises. “The comfort of wearing the headset for longer periods has improved significantly,” Keil says.

“It’s also great to see that the latest version of the Varjo headset now includes a chin strap. Particularly customers like loadmasters working in the rear of helicopters have mentioned that they occasionally need to look underneath the aircraft, and they can now do this in mixed reality.”

Additionally, the reoriented passthrough cameras of the XR-4 are now focused on the lower field of view, further supporting helicopter training where pilots must clearly see controls and instruments below the direct line of sight. “I believe this has been well implemented in the optical design and field-of-view layout of the Varjo XR-4 Series,” Keil notes.

 

High-Fidelity Training in a Compact, Cost-Effective Format

Mixed reality brings several advantages over traditional training methods, the most significant being its ability to replace large, expensive training devices with compact, cost-efficient systems. This “shrinking of the training devices” makes high-quality aviation training far more readily available and contributes directly to flight safety, as it enables more frequent, realistic training sessions.

Another key factor is the level of immersion that mixed reality provides across different training scenarios. “Personally, I love seeing pilots come out of a training session breaking a sweat because they were so absorbed in the experience that they forgot they weren’t in the real world. That’s when you know the simulation feels real,” says Keil.

Using the Varjo XR-4 devices’ passthrough mixed reality, pilots can see their own and their co-pilot’s hands interacting with real cockpit controls, which creates natural situational awareness just as in an actual aircraft.

According to Keil, mixed reality is the only way to combine tactile realism with a dynamic virtual environment. “Our customers have been very clear: pilots need a real cockpit environment. They need the haptic feel in order to conduct proper training and be fully immersed in the situation.”

 

“With our mixed reality simulator now in place, we see this as the starting point for an entirely new phase of development. We believe this could pave the way for a complete family of mixed reality-based training devices.” Martin Keil, Chief Technology Officer at Reiser

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