This study explores the impact of aviation experience on cognitive and physiological responses during simulated flight scenarios, focusing on heart rate, cognitive workload, and facial temperature. This research builds on previous studies showing how experience helps manage stress and cognitive demands in aviation. We did two experiments at different times divided into two experience groups: Experts, consisting of licensed pilots and pilot engineers, and Novices, including individuals with and without simulation experience. Participants completed Airbus A320 takeoff simulations under normal and emergency conditions. The study employed a Split-Plot Design, with experience level as the between-subjects factor and flight scenarios as the within-subjects factor, comprising two rounds of six scenarios repeated twice. Results reveal that experts exhibited lower stress levels and cognitive demands than novices, especially in high-pressure conditions. Furthermore, a learning curve effect was evident, as repeated exposure reduced stress and improved performance for all participants. These findings underscore the importance of experience in managing cognitive and physiological demands, offering actionable insights for designing pilot training programs that emphasize gradual exposure and stress management to enhance safety and adaptability.