Understanding Force Feedback in Sim Racing Controllers

What “Force Feedback” Actually Means in Sim Racing

Force feedback (FFB) is the translation of virtual physics into physical resistance. When a car in a game loses traction, hits a curb, or transfers weight through a corner, those simulated forces are calculated in real time and sent to your hardware.

The controller then uses an electric motor to generate torque, twisting or resisting against your input, to make you feel what the car feels. It’s not just vibration. It’s controlled motion, based on continuous data loops between the game and the hardware.

The Core Components of Force Feedback Systems

A proper force feedback setup, whether in a full-size wheel or a compact controller, relies on three pillars:

| Component | Role | Example in Milantec MK1 GO |

|-----------------------|--------------------------------------------------|----------------------------------------|

| Motor | Converts electrical signals into torque. | Brushless motor with direct-drive output |

| Sensor (Encoder) | Measures steering position and feedback accuracy. | Magnetic encoder (12-bit precision) |

| Controller Board | Interprets FFB data and drives the motor accordingly. | Custom PCB and controller board |

These three components form a closed loop:

1. The game sends a torque command.

2. The controller drives the motor.

3. The encoder reports the new position.

4. The board adjusts torque instantly to match target forces.

   
   

This happens hundreds of times per second — usually 200-1,000 Hz, depending on the system.

How Force Feedback Motors Work

Force feedback motors operate on torque control, not speed control. Unlike standard DC motors used in toys or vibration packs, FFB systems use brushless DC (BLDC) or AC servo motors for precision, linearity, and silent operation.

These motors are tuned to output specific levels of torque measured in Newton-meters (N·m):

• Entry-level wheels: ~2–5 N·m

• Direct-drive systems: 10–25 N·m

• Compact handheld units (like MK1 GO): ~0.1–0.3 N·m

  
  

Torque is regulated through a process called Field-Oriented Control (FOC), which manipulates current vectors to produce smooth, consistent force instead of jittery on/off pulses.

Translating Game Physics to Real Feel

Every sim racing game, like iRacing or Assetto Corsa, outputs effect parameters such as spring, damper, friction, sine, and periodic forces. A force feedback driver or HID firmware blends these effects into a single torque curve. The controller interprets this and updates the motor accordingly.

For example:

• Spring pulls the wheel back to center.

• Damper resists fast motion.

• Friction emulates mechanical drag.

• Collision effects add short bursts of torque.

  
  

The art of FFB tuning lies in balancing realism and responsiveness — enough torque to feel connected, but smooth enough to prevent oscillations.

The Challenge of Going Wireless

For years, wireless FFB was considered impossible due to latency and bandwidth limits. A traditional USB wheel might update at 1 kHz; wireless needed to stay under 10 ms total delay to feel natural.

Recent advances like low-latency 2.4 GHz protocols now make this feasible. The key is predictive filtering and packet compression, allowing a wireless controller to deliver stable, real-time feedback with minimal delay. The result is a wireless force feedback controller that feels almost indistinguishable from a wired setup but can travel with you anywhere.

Engineering Compact Force Feedback

Shrinking FFB technology into a handheld racing controller requires solving multiple trade-offs:

• Torque vs. Weight: Smaller motors produce less torque.

• Heat vs. Efficiency: Smaller housings trap heat.

• Latency vs. Stability: Faster updates risk noise.

• Battery vs. Power Draw: Managing current so that full torque doesn’t drain the battery instantly.

  
  

This is where embedded engineering meets mechanical design — achieving realism through control logic rather than brute-force power.

Inside the Feedback Loop (Simplified)

This continuous cycle is why even a compact system can replicate the subtleties of a car’s steering rack or tire scrub, not by guessing, but by closing the loop thousands of times per second.

The Future of Wireless Force Feedback

As we look ahead, the evolution of wireless technology will continue to enhance the experience of sim racing. Imagine a world where you can take your racing setup anywhere without sacrificing the immersive feel of force feedback. This is the future we’re working towards at Milantec.

Final Thoughts

Force feedback isn’t just a feature; it’s the language between the driver and the simulator. As wireless and embedded technologies evolve, we’re approaching a point where realistic, physics-accurate steering feel can exist in devices that fit in your backpack.

Understanding the mechanics behind FFB isn’t just about hardware specs; it’s about preserving what makes racing feel real. And that’s the philosophy driving every design decision at Milantec.

About Milantec

Milantec is a young company, founded in November 2024 by Magnus Clausen, who is just 17 years old. We are proud to be the youngest team ever accepted into the Danish Tech Challenge. Our flagship product, the Thumpdrive, is the world’s first wireless handheld force feedback racing controller.

Our family engineering team includes:

• Nicolai Clausen (Dad): Mechanical engineer with over 20 years at Oticon.

• Oliver Clausen (Brother): CO-CTO and software engineer.

• Bjarne Tholund: Senior software engineer specializing in embedded systems.

• Magnus Clausen: Founder/CEO coordinating development and community.

  
  

With the support of our business advisory team, we aim to revolutionize sim racing by making immersive force feedback accessible and portable.

Timeline of Our Journey

• November 2024: Milantec founded.

• 2022-2024: Prototyping and development phase before official company launch.

• June 2025: First Reddit posts with over 60K views.

• August 2025: Acceptance into the Danish Tech Challenge.

• Q1 2026: Planned Kickstarter campaign.

  
  

Milantec may be just 9 months old, but our product development and prototyping have been in the works for nearly three years. We are excited about what lies ahead!