In the aerospace industry, precision and reliability aren’t just desirable— they’re essential. Printed circuit board (PCB) assemblies are at the very heart of this field. Delicately engineered and endlessly versatile, these specialized electronic pieces are the thin line separating a successful mission from a potential disaster. They contribute to the efficient and safe operation of all types of aerospace installations, from planes to satellites to space missions.
The assembly of aerospace PCBs is, therefore, a process that leaves no room for error. This task calls for utmost precision, experience, and adherence to quality standards. As aerospace technology continues to reach new heights, so does the complexity and importance of PCB assembly in this challenging yet exciting industry.
How PCB Assemblies Are Used in Aerospace
The application of PCB assemblies within the aerospace industry reaches across multiple disciplines. Although PCBs differ in their specific use, they help power and control some of the most important aspects of aviation.
Here’s a look at some of the most compelling applications:
- Control Systems: A critical role of PCBs in aerospace lies within control systems. These boards help manage and regulate different operational aspects within airplanes, spacecraft, and satellites, ensuring systems run smoothly and efficiently.
- Communications: Unsurprisingly, PCBs play a major role in maintaining communication within aerospace systems. From enabling aircraft’s link, to air traffic control or promoting interstellar contact between spacecraft and mission control, they are indispensable for successful communication.
- Navigation: PCB assemblies are essential to aerospace navigation systems. They power GPS technologies and radar systems, which are fundamental for precise navigation and tracking.
- Guidance: The precise guidance needed for space shuttles and other aerospace vessels comes from expertly designed PCBs. They help provide vital data, such as velocity, orientation, and location that are used to accurately control and guide these vessels.
- Power Supplies & Sensors: Aerospace power supplies and sensor technologies rely heavily on PCBs. These assembled circuit boards ensure various systems have the necessary power to operate effectively while monitoring critical data like temperature changes, pressure levels, and radiation exposure.
The Many Challenges of Aerospace
Aerospace is one of the most demanding industries for manufacturing, particularly when it comes to PCB assemblies. Manufacturers face several challenges when creating these components, and overcoming them requires an equal measure of innovation and durability.
Challenge #1: Temperature Variation
One of the greatest challenges is the extreme temperature variation to which PCB assemblies will be exposed. In the confines of an aircraft or spacecraft, PCB assemblies may be subjected to harsh cold and intense heat within short periods.
Challenge #2: Vibrations
Vibrations during flight can also pose significant issues for these fragile components. PCB assemblies must be durable and resistant to these vibrations to avoid critical issues, such as solder joints weakening or breaking, leading to intermittent connections or complete circuit failure. Additionally, vibration-induced damage can compromise the integrity of the PCB’s delicate components, resulting in malfunctions that may affect crucial flight operations, such as navigation, communication, and control systems.
Challenge #3: Lightweight
In addition to being durable, PCB assemblies must be lightweight. This is very important because, in aerospace, every additional gram can mean increased costs for fuel and decreased payload capacity.
Challenge #4: Rigorous Industry Standards
Apart from the physical difficulties inherent in creating a reliable, efficient PCB assembly for aerospace applications, there’s also the matter of compliance with rigorous quality standards. These stringent standards ensure that every part used in an aerospace application performs optimally, even under harsh conditions.
Overcoming These Challenges
Manufacturers overcome these challenges through a variety of methods, such as high-temperature laminates that provide the endurance needed to face harsh thermal conditions combined with advanced copper plating techniques, which improve the unit’s heat dissipation capabilities.
Additionally, miniaturized components are increasingly used in PCB assemblies to ensure units are as lightweight as possible without compromising their functionality and durability.
Manufacturers may also earn IPC 610/620 Class 2 & 3 and AS9100 certifications to ensure compliance with strict standards. These certifications are universally recognized and provide reliable benchmarks for quality and performance.
At PGF Technology, we help our aerospace clients overcome these challenges by using materials that withstand extreme temperatures, optimizing thermal usage for resistance management, and effectively spacing high-power components to maintain the integrity of PCBs under demanding conditions.
How PCB Assemblies Are Designed & Customized
Because there is limited space within an aircraft or spacecraft, PCB assemblies must have compact and efficient designs that can integrate multiple electronic components. These assemblies must be remarkably resilient and capable of withstanding the severe conditions in both terrestrial and extraterrestrial environments.
With this in mind, PCB assemblies are customized through a comprehensive process. It starts with collaborative design and prototyping involving material selection, PCB fabrication, assembly steps (like soldering), and rigorous quality inspection. A particular focus is placed on the choice of materials, such as FR4 and glass-reinforced epoxy, known for their durability, conductivity, and temperature resistance.
The design must ensure the PCB can withstand a wide range of operating temperatures, vibrations, and radiation levels at high altitudes and withstand physical stress during takeoff and flight.
Learn More From PGF Technology
PGF Technology is an electronic manufacturing solutions provider that delivers unparalleled quality, service, and competitive pricing. We’ve been a trusted name in the industry since 1970 and have demonstrated an unwavering commitment to innovation.
We specialize in manufacturing many high-quality components, including PCB assemblies, for many industries, including aerospace. We also hold many certifications to ensure quality. These certifications include ISO 9001:2015, ISO 13485:2016, and IPC 610/620 Class 2 & 3.
Please visit our website for more PCB assembly resources or contact us today to learn more about our manufacturing capabilities.
