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Demand for PCBs in the aerospace industry is increasing, as the sector concentrates on improving efficiency, raising safety standards and meeting sustainability goals.
Electronic systems have always been an integral part of the aerospace industry, playing a critical role in the functionality of technology, both on the ground and in the air. Consequently, PCBs are fundamental to the future evolution of the sector.
PCB standards in aerospace industry
Many aerospace systems need PCB assemblies, which are used in technology and equipment right across the board. An exceptionally high quality is required in every application, and everything must conform to standard AS9100 – a quality management system adopted across the aerospace sector.
Introduced in 1999, by the European Association of Aerospace Industries and the Society of Automotive Engineers, AS9100 defines the design and manufacturing requirements of aerospace products including components, parts and assemblies.
Printed circuit boards must provide complete reliability, even in the harshest operating conditions. In the PCB assembly sector, manufacturers must comply with the IPC-A-610 standard. This establishes guidelines for creating and manufacturing better electronics assemblies.
In the aerospace industry, PCB assemblies must be able to withstand the severe radiation effects on electronics because of the highly radioactive environment of low-earth orbits, the outer-space environment and the associated temperature extremes. For certain projects, the circuit boards must be able to operate at temperatures as low as -55°C.
The PCB must also be durable enough to withstand vibrations onboard an aircraft, the impact of take-off and landing, and continual high-speed movement. Consequently, PCB testing for the aerospace industry is particularly stringent.
Manufacturers use a process called radiation hardening to make the electronic components and circuits highly resistant to the malfunctions or damage that can be caused by high levels of ionising radiation while in flight.
Copper PCB boards made using heavy copper technology are the norm, with the thicknesses ranging from 2 oz/ft2 to 6 oz/ft2 or even thicker. This enables PCB heat dissipation to occur naturally during circuit board soldering, without using any additional cooling system, even when high intensity currents are present.
Many manufacturers use heavy copper solutions on numerous layers to further improve heat dissipation, while creating a multilayer PCB. Compared to traditional PCBs, the distance separating the components can be increased, which can provide a greater volume of space to dissipate the heat.
Skilled PCB assemblers can create almost any prototype to provide a solution for even the most complex applications.
Aerospace applications for PCBs
Aerospace industry applications that require the highest-grade PCB assemblies include aircraft control systems, navigation systems, on-board avionic instrumentation, temperature sensors and satellite communication systems. They are also used at ground stations for processing the data recorded during missions or flights.
Printed circuit boards are needed for passive detection systems, unmanned aerial vehicles, radar installations and in-flight power supplies, including auxiliary power units.
Industry experts are designing PCB assemblies to power the next generation of aviation technology. The sector is heavily investing in the increased safety and efficiency of air travel in the future, with the goal of reducing its environmental impact.
Monitoring structural health is a key development area, with technology monitoring and assessing the aircrafts’ structural condition in real time This helps to identify the maintenance requirements, as well as avoiding potentially catastrophic failures.
Aircraft manufacturers are working towards reducing carbon emissions Their goal is to produce hydrogen-powered, zero-emission, commercial aircraft that could enter service as early as 2035. Currently, concepts are under development, with designers exploring new technology and aerodynamic configurations to achieve this goal.
PCB assemblers will need to keep pace with the advances in the aerospace industry and its long-term goals – it’s an exciting time for everyone involved!