Your Professional Aerospace PCB Manufacturer in China

Based on the number of layers, you would see three types of aerospace PCBs. They are:

1. One-Sided PCB

In a single-sided, or single-layer PCB board, you will find the mounted components on one side of the board. They are the most basic type of aerospace PCB and are used to build circuits for surveillance machines and switching relays.

2. Two-Layer PCB

In two-sided or double-layer PCBs, you will have two layers of mounted components. They are more advanced than single-sided aerospace PCBs and are widely used in manufacturing power supply devices. You can see a double-sided PCB in LED lighting also.

3. Multilayer PCB

Multilayer PCBs are the most complex type of PCBs. These PCBs contain more than two layers (at least 3) of conductive materials.

Multilayer Aerospace PCB

These boards provide the designer more flexibility to add functionalities to the devices. Moreover, they are also used in devices with GPS technology for the aerospace industry.

The following industry standards are applied to aerospace PCB development

ISO 9100 – This is a globally recognized ISO (International organization of standardization) QMSs baseline to derive other standards. This standard is open to any organization for customer satisfaction. QMS processes, higher management responsibilities, and ongoing improvement.

Aerospace PCB Manufacturer Must Be Iso Certified

SAE or the Society of Automotive Engineers also introduced a set of standards for aerospace PCB development. They are:

AMS2750E – This standard covers the device’s pyrometric requirements: instruments, thermals sensors, thermal processing appliances, and assessment: observing and investigating to confirm coherence to heat treatment specification.

AS478N – Defines the marking type and where to locate them for aerospace components.

AS5553A – This standard sets the general requirements for every organization in the supply chain (integration and procurement).

AS9006A – Determines software and other supporting components of the software. This also includes any devices or components that can be a part of the software or uploaded to the aerospace system.

AS9100D – Determines the QMS conditions for aerospace industry suppliers. It also covers the manufacturing process (in-house or outsourced), customer satisfaction, and management responsibilities.

AS9101E – Covers the QMS guidelines for reporting and auditing.

AS9102B – List’s baseline FAI (First article inspection) criteria.

** Other standards or guidelines developed for multiple industries are not listed above.

From the above list, you can see that significant industry standards are applied to the aerospace industry’s electronic component manufacturing process. But which standard controls which part of the manufacturing? For better understanding, we have created a table describing which standards are used in which manufacturing process.

Know more about design standard

Here is the list of most common aerospace PCBs that you can see in most applications:

● Rigid PCB

You can never twist or fold a Rigid PCB into another shape. You will find rigid PCBs in auxiliary power units. Cockpit instruments of an airplane, temperature sensors, and power converters use rigid PCB.

Moreover, they are widely used in manufacturing control tower instruments.

● Flexible PCB

As the name suggests, flexible PCBs are flexible, and you can twist them easily. They are made of plastic substrates like polyimide. They are widely used as connectors in different applications in the aerospace industry.

● Rigid-flex PCB

Rigid PCBs use both flexible and rigid board technology. These PCBs come with minimal weight and occupy less space. The features of Rigid PCBs make it an ideal choice for the aviation industry.

● RF PCB

In the aviation industry, radiofrequency PCBs are mandatory. They are responsible for making communication devices that pilots use for seamless communication.

● High-Speed PCB

Physical features of high-speed PCBs such as layout, packaging, and interconnection impact signal integrity.

 High-Speed Aerospace PCB

The aviation industry uses high-speed PCBs to manufacture those communication devices that are considered highly reliable.

● Metal Core PCB

In the metal core PCB, you will see metal at the core. Mostly aluminum, copper, and steel alloy are used in metal core PCB. These PCBs can manage heat very efficiently, and aviation industries use them to increase heat dissipation.

● Aluminum PCB

Aluminum can dissipate heat very efficiently and does not cost more. In the compression and decompression process, airplanes generate a considerable amount of heat, and aluminum PCB boards disseminate them.

● HDI PCB

High-density interconnects, or HDI PCBs can make lighter and faster products. These PCBs can integrate Microvias leveraging blind vias.

Before you invest in aerospace PCB, you should know the features very well. Here are the characteristics of Aerospace PCBs.

Handles Extreme Conditions Efficiently

As we have described earlier, you need solid PCBs for the aerospace industry. They should be more sturdy than the standard PCB you see in typical electronic devices.

Boeing Plane

Aerospace devices deal with lots of heat, and the copper and aluminum substrates with high-temperature laminates tackle that temperature. For proper heat transformation, you will also see thermal compounds in an airspace PCB.

Reliable PCB Material

Manufacturers integrate additional features in the fabrication and design process of aerospace PCBs. For heat dissipation, they apply thermal compounds, for example, aluminum.

Critical traces have to be grounded or shielded. As they are open to hostile situations, manufacturers spray them with acrylic spray.

Withstand Shock

In the aerospace industry, extreme vibration and shock are common phenomena. Manufacturers alter the board’s design to counter those vibrations and shocks.

Here you will see pins instead of soldering. This way, the board holds its component tighter. Sometimes both pin and soldering are applied.

Reliable and Durable

The most crucial factor of aerospace PCBs is reliability. Aviation electronics have to go through an aggressive environment, and they have to transmit satellite signals without interruption or failure.

Aerospace PCBs Should Be Durable And Reliable

Consequently, the aerospace PCBs are built with sturdy substrates, and manufacturers pin or solder the components firmly on the top of the board to stay there intact for a long time.

Can Withstand Radiations

Outer space PCBs have to face a high level of radiation, and that can damage the PCB board easily.

On that account, the design of Aerospace PCBs must be radiation preventive. To achieve that, manufacturers apply anti-fuse technology, which enhances radiation tolerance.

Can Tackle Varying Frequencies

The aviation industry depends on radio waves for communication purposes. And Those signals must be transmitted regardless of the environment or situation.

The antenna and strategic places need to be shielded. The transmission lines are shorter to establish constant transmission.

Rust Resistant

Manufacturers cover the exposed copper area with an invisible coating, including solder masking and aerosol coating.

Epoxy coatings are also used sometimes because they can create practical barriers to oxidation resulting in corrosion.

The coating must tolerate the thermal specification of the aerospace PCB.

Withstands Aerospace Standards and Protocols

Aerospace PCB manufacturers have to meet the standards. We have mentioned the criteria earlier in this article. Every aerospace manufacturer has to maintain those standards in every layer of the manufacturing process.

Optimizing Capability

After tackling the fluctuating temperature, the aerospace PCB also has to be corrosion resistant. Manufacturers have to use suitable materials to achieve that property.

In outer space, devices have to endure temperatures as low as minus 150 degrees Celsius. Apart from that, in space, there is no air that will transfer heat. In that case, only radiation can transfer heat.

Aerospace Pcb Can Work In Minus 150 Degree C

Manufacturers utilize unique high-temperature laminates, aluminum, and copper substrate in an aerospace PCB to tackle this situation. Manufacturers also use some thermal compounds so that heat can not transfer to other electronic parts. Components are twenty-thousandths of an inch distant from the surface of the board. Fans are also used to disseminate extra heat.

For making an aerospace PCB more robust, there are specific design and layout considerations to follow.

Aerospace PCB Circuit Diagram

You have to utilize the appropriate mil-spec components. You will also have to consider current, among other crucial factors, and design additional cushions accordingly.

• First, you have to secure the additional current that the PCB circuitry will generate.
• You have to design the PCB in such a way that it can carry additional amperes if the other two fail.
• Assign the aspect ratio to deal with the bare board’s balance according to the vias when you drill the latter. The ratio should be 1:10; if you exceed that, that will endanger the reliability.
• When designing, you have to separate the ground planes and power. You have to separate low and high-frequency ones.
• Oscillating components are likely to produce waveforms when using those at high frequencies and can affect lower frequency components.
• Shield and make sure the clock signals are clean. You can use aluminum or similar materials to achieve that.
• Now you have to verify the impedance calculations. As you can not test aerospace applications in a familiar environment, you must run pre-layout simulations.
• You have to use simulation software to make it possible. Thus you will be able to achieve standard recommendations or alter the design accordingly. And you will be able to know whether your PCB is working optimally or not.
• Maintain a strict 45-degree angle in the process of trace routing your aerospace PCB. Curved traces can transmit currents within the circuitry smoothly, which is why they are mostly preferred.

You have to do cushioning to the mechanical holes for strength and efficiency.

You can use FR4, G10, or Cyanate Ester for low-frequency applications. For high frequency, you have to use the Rodger series, Droids, and Teflon-based materials.

Learn more about PCB manufacturing

The fabrication process of aerospace needs some unique treatments compared to the standard PCB fabrication process. You have to perform some additional developments in every stage of traditional PCB fabrication. Here are the steps:

• Sequential Limitation– You have to complete this process with polymer matrix composites. They are light and stiff but resistant to heat.
• Blind and Buried Vias– You will use these to connect PCB layers to connect the outer and inner layers. Buried vias connect outer layers without penetrating them.
• Filled Vias – You have to use non-conductive and conductive filled vias to protect them from solder or other contaminations. It also works as structural support to the copper pad.

PCB Fabrication

• Stacked Vias and Laser Drilling – Laser drilling is essential in the aerospace industry to create vias. It is also applicable for composite materials and FR4.
• Heatsinks– For insulting the heat sinks, you have to use high-grade thermal compounds. This process is vital for pad PCB boards and ensures lesser vibration.
• Castellation and Edge Plaiting –
• Edge Plaiting and Castellation – This allows aerospace PCB’s modification. You can drill a hole more efficiently and create milling slots.
• Thermal Compound Application – As thermal compounds insulate heat sinks, you have to apply them. Aerospace PCBs can be exposed to different temperature levels.
• Soldering of swages– You have to use this in the soldering of aerospace PCB.

Some of the processes of aerospace assembly are as follows:

Designing

For perfect execution in the manufacturing process, the planning and designing phase is crucial. You should follow every step carefully in the design and layout process.

You have to check every specification that can cause flaws.

Solder Paste Application

You have to apply solder paste on the board. Stencils are used here to create different sizes and shapes.

PCB Assembly

Components Placing

This automatic process enables component placement on the board’s targeted areas. Robotics machines are used in this process as they are operated by software.

Solder Paste Application

You have to apply solder paste properly after you are finished with component placement. Conveyor belts are used to put through the aerospace PCB and go through a reflow oven. You have to use a standard industrial oven to augment the excess solder paste melting.

Then they are revealed to cooler heaters to cool down and solidify melted paste and hold the board’s component firmly.

Inspection

At this step, you have run an inspection to identify any functionality issue. A Poor quality connection can lead to an operational flaw. The first check is done manually, and then digital machines are used.

Component Insertion

Through-hole insertion is required for aerospace PCB components because the aerospace industry primarily uses multi-layered PCBs. This process ensures the signals can pass through from one side of the board to the other side.

Final inspection

In the final stage, you have to check the electrical properties and functionalities. This process includes current and voltage inspection. Single outputs are also considered in this inspection. As the plane can be exposed to various risks, any flaw in this stage can be disastrous.

Cleaning

Cleaning the aerospace PCB is crucial as any residue can interfere with the functionality and cause harm. You have to use deionized water to wash the board and dry it with compressed air.

When you are finished with the assembly process, it’s time to test your aerospace PCB. This is a crucial step and MUST be performed as aerospace PCBs are too sensitive.

A tiny error can cause a drastic failure and translate into disaster.

In the testing process, you have to confirm that the aerospace PCB follows the design specification and standards of the aerospace industry. It also helps to identify the PCB has achieved desired features appropriately.

PCB Testing

In most cases, a prototype PCB is manufactured, and the manufacturer can detect flaws during the prototyping process.

As aviation products are too sensitive, manufacturing the final product before prototyping is never recommended. The production PCB must go through the prototyping process.

Before rolling out for final production, the prototype MUST meet all the requirements and standards provided by the aviation industry.

Packaging aerospace PCB is a sophisticated process.

PCB Packaging

Aerospace PCBs have to be adequately packaged to prevent any damage. The slightest damage can occur in a catastrophic occurrence in the future. In the shipping process, special boxes are needed for special protection.

The cushion should be used in the box to prevent internal movement; otherwise, the result can be destructive.

Aerospace PCBs are used in various devices in the aerospace industry. Some of them are:

Radio Communication Systems

In the aerospace industry, radio communication is a must. This helps communication between the control tower and the crew. Aerospace PCB makes that communication efficient and seamless.

Airplane Communication System

Radar Installations

Radio waves are transmitted through radar installations, and for communication purposes, these are crucial. Aerospace PCBs are mandatory in this installation, and they are highly resistant against vulnerable weather conditions.

Aerospace Sensor

Sensors detect pressure, signals, heat, etc., and therefore are crucial in the aerospace industry. Sensors need to be reliable and stable, and at the same time, cost-effective. Aerospace PCBs offer those qualities.

Power Converters

Power converters convert electricity from one form to another form, and in the aerospace industry, these are very sensitive.

For example, space shuttles depend on this to fly in space. Therefore, any type of flaw or failure here will be catastrophic.

Converters made with aerospace PCBs are made in such a way that they can handle space radiation to ensure efficiency.

Power Supplies

A power supply supplies power to the electric boards. So, failure is never an option in this case. Aerospace PCBs designed for power supply can handle power fluctuation.

LED Lighting Systems

The aviation industry widely uses LED lights, and aerospace PCBs are used to manufacture those lights. Any flaw in the LED lighting system will be catastrophic so that delicate aerospace PCBs are used to manufacture LED lights for the aviation industry.

Flight Instrumentation

You will find this in the flight deck to electronically display flight data. It is also a very sensitive plane component. Aerospace PCBs used here must be highly durable.

Temperature Sensors

These devices measure and send data to display temperature. Airplanes face fluctuating temperatures, and these data must be accurate.

Aerospace PCBs used to build these sensors must be able to endure fluctuating temperatures.

Engine Control Systems

These PCBs help to operate the engine efficiently and need extreme heat endurance.

Audio Interface Applications

The flight data recorder is a good example here. This equipment records every spoken information over the radio. They also store data, and in case of an accident, that data helps to find out the exact reason for the occurrence.

Before finding the best Aerospace PCB manufacturer, you should consider the following:

Professionalism

The supplier must be an expert in aerospace PCB. You can ensure that from the provider’s certification. If they are certified by relevant aerospace bodies, then you can trust them. The

Spacecraft and airplane PCBs must be made with professional expertise. Therefore, the staff also have to be certified experts.

Thus you can guarantee quality PCBs and avoid any hazardous outcome.

Experience

Experience is also a mandatory factor while choosing an aerospace manufacturer. Experienced manufacturers can ensure reliability in the fabrication and assembly processes.

So, search for an experienced manufacturer who works with a professional workforce.

Aerospace PCB Manufacturer

High Tech Technological

Advanced technology ensures product quality and efficiency. And technology is evolving day by day. New technology finds the errors of previous technology and corrects them. So, find a manufacturer who uses the latest technology in the manufacturing process.

Warranty

Aerospace PCBs are not cheap. They are built to tackle numerous environmental phenomena. So, a warranty is mandatory when you are finding a manufacturer. The warranty also shows the manufacturer’s confidence in his products.

Shipping

The manufacturer should be able to work with logistics and freight forwarders to transport your PCB shipment safely and secured. The packaging process and monitoring the shipping process are also crucial because a silly mistake can be costly.

After-Sales Service

You should also consider their after-sales service. If anything happens to your PCB, how promptly they react to your query and offer replacement is also considerable.

Other Factors

Quick response

Provides detailed guideline on how to use their PCBs

Provides a client list so that you can cross-check their product quality.

Aerospace PCBs are essential in the aviation industry, and you have to consider several factors before investing in these PCBs. From the design to production, every process is delicately handled.

Aerospace PCBs must be durable and reliable. We have described the design, fabrication, and assembly process. You should pick your aerospace manufacturer carefully to ensure PCB quality.