- More than 6,000 square metres bringing together engineering, design, development, production, assembly, integration and testing
- Capacity for up to five simulators at a time, expanding Leonardo’s industrial and technological capabilities in advanced flight training systems
- Workforce growth supports the expansion of skills and expertise: more than 610 employees in 2025, up 30% from 2022
Leonardo today opened a new building at its Sesto Calende facility dedicated to the development and manufacture of helicopter flight simulators. The investment builds on the training technologies and services available at the site since 2006, when the “A. Marchetti” Training Academy opened as Leonardo’s first helicopter training academy. It further establishes Sesto Calende as a development and production hub for simulation systems across the Company’s rotary-wing business.
The building provides more than 6,000 square metres of space and can accommodate up to five simulators at a time. It brings engineering, design, development, production, assembly, integration and testing together under one roof, strengthening the site’s capabilities across the full simulator development and manufacturing cycle. Offices occupy three floors alongside a large assembly and integration area. The most advanced simulators recreate a helicopter cockpit on a motion platform or fixed base, surrounded by a panoramic visual dome.
The project builds on the facility’s growth in recent years. Employee numbers rose from around 470 in 2022 to more than 610 in 2025, an increase of over 30%. The new building will bring together specialists currently working across different areas of the site, including aeronautical and computer engineers, software developers, assembly technicians, pilots and programme managers. These include many young professionals with STEM skills, particularly in engineering and software development, reflecting the site’s ability to attract and develop skilled talent.
Simulator design and manufacturing have long been core areas of expertise at Sesto Calende. Leonardo-developed systems include the A129 Mangusta helicopter simulator for Italian Army Aviation in Viterbo, the HH139 simulator for the Italian Air Force in Cervia and the NH90 helicopter simulator at the Italian Navy’s Maristaeli Luni simulation centre. The site has also developed systems for other helicopter types and customers worldwide.
The new building provides additional space to expand these activities and develop systems for civil and military programmes in Italy and overseas. The first simulators built in the new facility will serve operators in Italy and Asia. Stronger in-house capabilities will continue to complement established industrial partnerships with specialist companies, including the Rotorsim joint venture with CAE. Expanded capabilities for independent development will complement these partnerships to open up new markets and meet the full range of customer requirements.
The expansion supports an important part of Leonardo’s helicopter business: between 2023 and 2025, Customer Support, Services & Training accounted for an average of around 42% of Helicopters revenues. Across Leonardo’s helicopter training activities, more than 16,000 people are now trained each year.
The Sesto Calende Training Academy uses advanced simulation systems to train pilots, crews, operators, ground staff and maintenance personnel. These systems recreate flight, missions, maintenance and repair tasks with a high degree of realism. More recently, they have supported the development of new scenarios and programmes. Digital technologies, including virtual and augmented reality, artificial intelligence and digital twins, enable multi-domain scenarios and allow personnel to train safely in complex situations. Simulation also helps reduce costs, improve environmental and economic sustainability, and keep aircraft available for operational duties.
The facility also houses the coordination centre for technical and logistics support across Leonardo’s entire helicopter fleet.
The new building continues Sesto Calende’s aviation heritage, which dates back to 1915. Alongside the site’s preserved historic buildings, new spaces for digital technologies and advanced simulation reflect the continued evolution of the local area’s industry, technology and skills.
Leonardo is an international industrial group that develops multi-domain technological capabilities for global security. A key player in the major strategic programmes in Aerospace, Defence and Security, it employs over 62,000 people worldwide and operates in the Electronics, Helicopters, Aircraft, Cyber & Security and Space sectors. The company has a significant industrial presence in Italy, the United Kingdom, Poland and the United States, and is active in 150 countries also through subsidiaries, joint ventures and investees. Leonardo is a technological and industrial partner to Governments, Defence Administrations, Institutions and businesses. Listed on the Milan Stock Exchange (LDO), in 2025 Leonardo recorded new orders of €23.8 billion, an order backlog of €46.6 billion and consolidated revenues of
€19.5 billion. Included in the MIB ESG Index, the company has also been part of the Dow Jones Sustainability Indices (DJSI) since 2010.
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