The present invention is a simulator for skill-oriented training. The simulator includes a work piece platform having a sensor, a head-mounted display unit (HMDU) including a camera, a speaker and a sensor providing visual and audio output to an operator, and a controller having a controller sensor. The simulator includes a processor that executes algorithms to simulate a virtual training environment depicting a work piece rendered on the work piece platform. The controller sensor, the HMDU sensor and the platform sensor output signals to the processor representing spatial positioning, angular orientation and movement data of the controller relative to the work piece to render a virtual powder coating spray pattern including a stream having particles charged and emitted from the controller and a powder coating coverage as applied to the work piece during one or more passes of a powder coating spray process performed by the operator.