The Role of Electronic Assemblies in the Aerospace Industry

Since 1970, PGF has been assembling box builds, cables, wire harnesses, and printed circuit board assemblies (PCBA) for a wide variety of industries. As an industry-leading contract manufacturer and aerospace assembly provider, we pride ourselves on guaranteeing exceptional service, unsurpassed quality, and competitive pricing.

Equipped with more than 50 years of experience combined with cutting-edge equipment and machinery, we have what it takes to provide quality assembly solutions for a broad range of applications.

PGF Technology Group, Inc. offers extensive PCBA, wire harness, cable, and box build assembly services for commercial and industrial markets, with a strong focus on the aerospace industry. Our experienced team works with customers to fully realize their aerospace designs, regardless of the complexity.

The Role of Box Builds in the Aerospace Industry

Box build assemblies in aerospace are pre-fabricated, pre-tested, and pre-assembled systems that are housed in a metal or composite enclosure. They consist of electronics, electrical, and mechanical components and are used for avionics, power distribution, cabin systems, fuel systems, and landing gear, among others. The enclosure protects from environmental factors and helps meet safety regulations. Box build assemblies are crucial for safe aircraft operation and reduce downtime and maintenance costs.

Applications of Cable & Wire Harness Assemblies in the Aerospace Industry

As the demand for electrification grows, we continue to grow with the industry, providing custom-made aerospace cable systems (often hand-assembled) and aerospace wire harnesses for numerous applications.

In the aerospace industry, cable and wire harness assemblies are vital for transmitting, connecting, and controlling electronic and electrical systems to essential components in the aircraft. The assemblies contain a bundle of organized cables and wires protected by shielding, insulation, and cladding materials to withstand harsh operating conditions often associated with aerospace applications, including vibration, high temperatures, and high altitude. The cables and wire harnesses can also help minimize clutter inside the aircraft, reduce weight, and contribute to improved efficiency and safety.

Some of the most common applications for cable and wire harnesses in the aerospace industry include, but are not limited to:

  • Avionics Systems: Connects communication, navigation, and flight control avionics systems to the data and power bus in the aircraft.
  • Power Distribution: Distributes electrical power to engines, lighting, instruments, and other systems within the aircraft.
  • Engine Controls: Transmits electrical signals to the engine management systems and engine controls for real-time monitoring.
  • Flight Controls: The pilot can control the aircraft by transmitting electrical signals between the aircraft’s control surfaces and flight control systems.
  • Environmental Systems: Monitors and controls the environmental systems of the aircraft, including pressurization, heating, and air conditioning.
  • Landing Gear: Monitors and controls the landing gear systems, including retraction and gear deployment.

Applications of PCB Assemblies in the Aerospace Industry

Several devices that utilize high-grade aerospace PCB assemblies include:

  • Advanced Short Range Air to Air Missiles (ASRAAM)
  • Advanced Medium Range Air to Air Missiles (AMRAAM)
  • Auxiliary Power Units (APU)
  • Control tower systems
  • In-flight power supplies
  • Instrumentation
  • LED lighting systems
  • Power converters
  • Power grids
  • Power switches
  • Radar installations
  • Radio communication systems
  • Signal sensors
  • Temperature sensors

Aerospace PCB Assembly Standards

When designing aerospace electronics, every component must have a set of characteristics capable of contributing to the overall manufacturing process of aerospace PCB parts. Each component must have a proper process with part performance that is both efficient and cost-effective. Other essential traits include adherence to regulations and guidelines. AS 9100 uses the ISO 9001 standards as its foundation in addition to other SAE standards that cover different elements of the aerospace PCB assembly process.

Design Considerations for Aerospace PCB Assemblies

Designers and aerospace engineers strive to develop innovative solutions for distributing adequate power reliably to all required systems. While high power usage presents unique concerns for aerospace PCB assembly, a well-designed power board can be achieved by:

  • Selecting board materials that withstand extreme temperatures
  • Achieving good resistance management by optimizing thermal usage
  • Effectively spacing high-power components apart from each other
  • Properly following the design rules for grounding
  • Using large copper weight for controlling current flow

Why Should You Source Your Electronic Assemblies From Only a Trusted Manufacturer?

The aerospace industry demands box builds, cables, wire harnesses, and PCBAs to be built to withstand extreme environmental conditions. Therefore, aerospace electronic assemblies must incorporate specialized features while adhering to the highest quality standards. Partnering with a leading aerospace PCB manufacturer ensures the assembly of high-grade PCBAs, which is crucial when striving to meet industry expectations.

Working with PGF Technology Group, Inc. provides customers with peace of mind they are working with an experienced company that utilizes the best machinery, materials, and advanced manufacturing techniques in the industry. You can also be confident you are partnering with a dedicated aerospace PCB manufacturer who assembles in compliance with all international standards relating to aerospace specifications.

Contact us to learn more about our aerospace PCB assembly services and electronic manufacturing procedures. You can also request a quote for detailed information on meeting the demands of your next application.

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