<h2 id="isPasted">Stay at the cutting edge of the aerospace industry</h2><p>We are pleased to have partnered with <a href="https://www.rocelec.com/" target="_blank" rel="nofollow">Rochester Electronics</a> to launch the Future-Proofing Aerospace whitepaper.</p><h3>Whitepaper highlights:</h3><ol><li><strong>Understand the Importance of Legacy Systems</strong>: Discover why preserving legacy avionics systems is crucial for reliability, compliance, and cost-effectiveness.</li><li><strong>Navigate Component Obsolescence</strong>: Learn about the challenges aerospace designers face due to outdated or discontinued components and how to address them.</li><li><strong>Explore Solutions from Rochester Electronics</strong>: Gain insights into how Rochester Electronics specializes in preserving and replicating obsolete components to ensure the continued operation of legacy systems.</li></ol><p>Download the full whitepaper below.&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIxMjIzMjk0OTEzLXJvY2hlc3RlciBtb2NrdXAzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://c8056756.sibforms.com/serve/MUIFAPvRjKP45aVx8DQkoObDXDWJw6rbmqP9ZmGK9hJM9glc0ZpymV0NWJzWgEQzqaBt_nJkeTn8a_kmy7xsfUjzIoMxZkEd-3YakGRA44TU4L7vmi9mzfI2Y4Ewa0e3CjvO8N62LazFWvnZ7611BzrvY8BHuhHcvUYCKM07CCfjHco_6Puwcdr4WsKo7J7_4yTPNhW-Z5L2mi2m" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block; margin-left: auto; margin-right: auto; max-width: 100%; width: 829px; height: 274px;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h3 dir="ltr">Solutions to component obsolescence</h3><p dir="ltr" id="isPasted">Throughout this article series, we’ve discussed the causes of component obsolescence and the significant risks it poses to the avionics designer. The extra time, money, and effort incurred due to obsolete components can completely make or break an avionics design. But now it’s time to talk about solutions.&nbsp;</p><p dir="ltr">At Rochester Electronics, they’ve made it their mission to help customers overcome the challenges associated with component obsolescence. In this piece, we’ll show you exactly how they have been helping avionics designers skirt the challenges of component obsolescence for over 40 years.&nbsp;</p><h3 dir="ltr">Authorized Distribution and Licensed Manufacturing</h3><p dir="ltr">One way to approach the challenge when dealing with obsolete components is to seek out specialized suppliers who focus on providing solutions for end-of-life (EOL) and hard-to-find electronics. The aerospace industry, in particular, faces significant hurdles in this area due to the long lifecycles of aircraft and the rapid pace of semiconductor evolution. This situation is further confounded by the prevalence of counterfeit parts in the market, which can lead to performance issues, safety risks, and compliance violations.&nbsp;</p><p dir="ltr">Rochester Electronics stands out above the competition thanks to its ability to provide a continuous supply of both active and end-of-life semiconductors through our authorized distribution and licensed manufacturing services<sup>[1]</sup>. Thanks to these partnerships, we have amassed an inventory of over 15 billion genuine devices. By having all components go through authorized distribution, we guarantee our inventories are free from counterfeit parts and that they all meet the original manufacturer's specifications.&nbsp;</p><p dir="ltr">To complement this, we also have the in-house capability to manufacture over 70,000 different device types. This enables us to ensure that aerospace companies can always access the necessary components without risking exposure to counterfeit parts.</p><p dir="ltr">By choosing Rochester Electronics as their partner, aerospace companies can confidently source the components they require for maintaining and repairing their legacy systems, knowing that these parts are authentic and reliable.&nbsp;</p><h3 dir="ltr">Wafer Storage and Processing</h3><p dir="ltr">Maintaining component integrity in storage is a big challenge for suppliers like us. During long-duration storage, semiconductor wafers and components are susceptible to a variety of degradation factors such as oxidation, moisture absorption, and electrostatic discharge. These environmental stressors can lead to subtle changes in the material properties of the semiconductors, potentially affecting their electrical characteristics, reliability, and overall performance. Without proper preservation techniques, even microscopic contaminants or slight variations in temperature and humidity can compromise the integrity of stored components, rendering them unusable for future manufacturing processes.&nbsp;</p><p dir="ltr">This is why we implement rigorous storage protocols and advanced environmental control systems. At Rochester Electronics, we pride ourselves on delivering cutting-edge wafer preservation and handling solutions<sup>[2]</sup>. Our advanced facilities in Newburyport, Massachusetts, boast ISO-8 and ISO-7/10 K-certified environments with nitrogen control, precise humidity regulation, and continuous temperature and moisture monitoring. These meticulously managed conditions safeguard wafers against contamination and deterioration so that we can maintain a robust inventory of components without the risks typically associated with extended storage periods.</p><p dir="ltr">Our comprehensive services encompass wafer back-side grinding, precision dicing using dual spindle saws, and thorough dice inspection utilizing state-of-the-art Automated Optical Inspection (AOI) systems. These advanced technologies allow us to offer unparalleled defect detection and measurement, ensuring strict adherence to the most rigorous quality standards in the industry. We further extend our offerings to include manual and automated pick-and-place operations conducted under ISO-5 hoods, providing individual dies in various packaging formats, including waffle packs, film frames, gel packs, and tape and reel configurations.</p><p dir="ltr">All of these efforts together guarantee that Rochester customers receive safe and reliable components.</p><h1 dir="ltr">Replication Services</h1><p dir="ltr">One of our most unique tools for fighting component obsolescence is our replication services, which allow us to replicate obsolete devices with authorization from original manufacturers [3]. &nbsp;</p><p dir="ltr">For instance, our Design team, with over 40 years of combined experience, specializes in authorized porting of<a href="https://rocelec.widen.net/s/txzqlbmhhd/product-re-creation-showcase_2018_flipversion" target="_blank">&nbsp;products from original fab processes</a>, including DO-254 minor change classification – which avoids the need for system recertification – and DO-178 compliance. To this end, we employ unique proof-of-duplication methodologies and advanced electrical performance replication techniques, such as output edge-rate matching and detailed signal integrity analysis. Our labs perform electrical device characterization of original and replacement devices across temperature and voltage limits. This rigorous process ensures that our ported products match the I/O performance of the original components, maintaining system stability and preventing the introduction of new signal integrity concerns. Our comprehensive approach includes legacy voltage ASIC designs for FPGA replacements and creative board-level solutions to support long-life systems.</p><p dir="ltr">By replicating obsolete components, we help aerospace companies avoid the substantial costs and risks of redesigning systems to accommodate new parts. Our ability to provide exact matches to original components guarantees the continued reliability and performance of aerospace systems, mitigating the impact of component obsolescence and supporting the long-term viability of your legacy designs.</p><h3 dir="ltr">Comprehensive Testing and Assembly Services</h3><p dir="ltr">Before components can be sold to customers, they must be fully tested and validated to ensure proper performance and adherence to standards. That’s why we’ve invested significant resources in cutting-edge testing equipment and modern assembly technologies. We expose all of our components to a comprehensive validation process that ensures all components meet or exceed performance criteria before deployment.</p><p dir="ltr">In terms of assembly, we maintain support for both traditional and cutting-edge technologies, encompassing lead frame, QFN, and BGA assemblies [4]. Our expertise spans both hermetic and plastic assembly methods. For hermetic assembly, we utilize automated and semi-automated equipment for eutectic, silver glass, and epoxy die attach processes, and we offer package replications including leadframes. Our plastic assembly line features automated saw, die attach, wire bond, and full automold equipment. We also provide component lead finishing services, including SnPb and 100% tin plating, with versatile rack plating systems and solder dip options. The quality of these processes is assured through DLA-certified procedures and in-house reliability testing.</p><p dir="ltr">Our testing capabilities are housed in a 30,000-square-foot facility equipped with state-of-the-art automated test equipment and computer-aided design systems [5]. At these facilities, we offer a wide range of testing services covering digital, analog, RF, memory, ECL, mixed-signal, ASICs, PLDs, and FPGAs. This includes specialized testing for military applications, enhanced screening procedures, up-screening, selected item drawing, source control documents, and tier-2 automotive testing. Furthermore, we provide bespoke, high-quality test solutions, temperature profiling, ATE platform conversion, component programming, and electrical and mechanical interface design.</p><p dir="ltr">By integrating these advanced capabilities, we create customized solutions that precisely meet the unique needs of aerospace companies, whether it involves testing legacy components or fabricating new ones to exact specifications. Our comprehensive approach minimizes obsolescence-related risks and guarantees that all components undergo thorough validation before integration into critical systems.</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">Component obsolescence is undoubtedly a challenge, but that doesn’t make it insurmountable. At Rochester Electronics, their combination of authorized distribution and licensed manufacturing, wafer storage and processing, replication services, and comprehensive testing and assembly services should provide customers with the resources and confidence needed to overcome the impact of obsolete components.</p><p dir="ltr">Learn more about aerospace obsolescence in the latest whitepaper.&nbsp;</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://c8056756.sibforms.com/serve/MUIFAPvRjKP45aVx8DQkoObDXDWJw6rbmqP9ZmGK9hJM9glc0ZpymV0NWJzWgEQzqaBt_nJkeTn8a_kmy7xsfUjzIoMxZkEd-3YakGRA44TU4L7vmi9mzfI2Y4Ewa0e3CjvO8N62LazFWvnZ7611BzrvY8BHuhHcvUYCKM07CCfjHco_6Puwcdr4WsKo7J7_4yTPNhW-Z5L2mi2m" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block; margin-left: auto; margin-right: auto; max-width: 100%; width: 829px; height: 279px;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><p dir="ltr">In the next article in this series, we’ll discuss some proactive strategies for managing avionics obsolescence.</p><h2 dir="ltr" id="isPasted">Read more in the series:</h2><p dir="ltr"><a href="https://www.wevolver.com/article/the-importance-of-preserving-legacy-systems-in-avionics" target="_blank" rel="noopener noreferrer">Article 1: The Importance of Preserving Legacy Systems in Avionics</a></p><p dir="ltr"><a href="https://www.wevolver.com/article/the-causes-of-component-obsolescence" rel="noopener noreferrer" target="_blank">Article 2: The Causes of Component Obsolescence</a></p><p dir="ltr"><a href="https://www.wevolver.com/article/customer-challenges-with-obsolete-components" rel="noopener noreferrer" target="_blank">Article 3: Customer Challenges with Obsolete Components</a></p><p dir="ltr">Article 4: <a href="https://www.wevolver.com/article/solving-obsolescence-with-rochester-electronics" target="_blank" rel="noopener noreferrer">Solving Obsolescence with Rochester Electronics</a></p><p dir="ltr">Article 5: <a href="https://www.wevolver.com/article/proactive-strategies-for-managing-avionics-obsolescence/draft" target="_blank" rel="noopener noreferrer">Proactive Strategies for Managing Avionics Obsolescence</a></p><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr"><a href="https://www.rocelec.com/solutions/licensed-manufacturing" target="_blank">https://www.rocelec.com/solutions/licensed-manufacturing</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.rocelec.com/news/comprehensive-reliable-wafer-storage" target="_blank">https://www.rocelec.com/news/comprehensive-reliable-wafer-storage</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.rocelec.com/news/moving-beyond-the-bom-rochester" target="_blank">https://www.rocelec.com/news/moving-beyond-the-bom-rochester</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.rocelec.com/solutions/manufacturing-services/assembly" target="_blank">https://www.rocelec.com/solutions/manufacturing-services/assembly</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://www.rocelec.com/solutions/manufacturing-services/test-services" target="_blank">https://www.rocelec.com/solutions/manufacturing-services/test-services</a></p></li></ol>

Futureproofing Aerospace Series. Article #4: Rochester Electronics has decades of experience helping customers navigate the complexities of component obsolescence.


Solving Obsolescence with Rochester Electronics

<h2 id="isPasted" data-element-id="headingsMap-4-0">Stay at the cutting edge of the aerospace industry</h2><p>We are pleased to have partnered with <a href="https://www.rocelec.com/" target="_blank" rel="nofollow">Rochester Electronics</a> to launch the Future-Proofing Aerospace whitepaper.</p><p>The aerospace industry is continuously evolving, driven by the need to modernize, improve efficiency, and drive down costs. However, as avionics – the electronic systems that power aircraft – continue to advance, the preservation of legacy systems becomes increasingly vital. This whitepaper offers critical insights into the importance of maintaining these systems, the challenges posed by component obsolescence, and the solutions available to navigate these complexities.</p><h3 data-element-id="headingsMap-5-0">Whitepaper highlights:</h3><ol><li><strong>Understand the Importance of Legacy Systems</strong>: Discover why preserving legacy avionics systems is crucial for reliability, compliance, and cost-effectiveness.</li><li><strong>Navigate Component Obsolescence</strong>: Learn about the challenges aerospace designers face due to outdated or discontinued components and how to address them.</li><li><strong>Explore Solutions from Rochester Electronics</strong>: Gain insights into how Rochester Electronics specializes in preserving and replicating obsolete components to ensure the continued operation of legacy systems.</li></ol><p dir="ltr" id="isPasted">One of the most pressing threats to the continuity of legacy systems is component obsolescence. Obsolescence occurs when a component is no longer produced, supported, or available from the original manufacturer, rendering it difficult or impossible to procure. This situation poses a significant risk to the ongoing operation and maintenance of aerospace systems, as finding suitable replacements can be challenging and costly.</p><p dir="ltr">Components can become obsolete for a myriad of different reasons, and often, a confluence of various reasons ultimately renders a component obsolete. Influences such as market trends, technological advancements, and economic pressures all come into play in this unfortunate but unavoidable part of the electronics lifecycle.</p><p dir="ltr" id="isPasted">At Rochester Electronics, we specialize in helping customers navigate the complexities of component obsolescence. Understanding the causes of component obsolescence is necessary for developing effective strategies to mitigate its impact.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE5NDg1MzQzODczLXJvY2hlc3RlciBtb2NrdXAzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://c8056756.sibforms.com/serve/MUIFAI58ML_0Jkq9ohSSVMrlfZ0o5Eup39aCZcy3V6OAZo33jakOcLECU6nQ3NIK9BP2kTGzF7l86SWC2L2j4CzrX7ON60erda6KYq1u3fkfZlqfqvx3n-tgHoSgZUr9MPV6ZCTY28OxdOhn8Fe0Sr2_Je6Hij8GIv-S5GMMYtVvFfZS2Eb2YYUeZ97JSsuW5lvaTW-dqGZytjXp" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block; margin-left: auto; margin-right: auto; max-width: 100%; width: 540px; height: 350px;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-headingsmap-frameid="1728"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h2 dir="ltr" data-element-id="headingsMap-7-0">Tester Platform Evolution</h2><p dir="ltr">An important aspect of the component manufacturing lifecycle is the testing procedures that confirm product quality and functionality. To this end, component manufacturers employ a variety of specialized testing platforms, which entail complex and expensive equipment. In this context, one of the largest causes of component obsolescence is the obsolescence of the underlying testing platforms.&nbsp;</p><p dir="ltr">Consider a component first developed in the 1980s. At the time of development, the testing equipment used in the manufacturing process was likely state-of-the-art, meeting the frequency, power, and communication protocol requirements to test the component under test accurately. Fast-forward to today, however, and what was considered state-of-the-art for the testers in the 1980s is likely extremely antiquated.&nbsp;</p><p dir="ltr">Modern semiconductor devices operate at higher frequencies and lower voltages while employing newly developed communication protocols that didn’t exist in the 1980s<sup>[1]</sup>. Naturally, a testing platform from antiquity cannot support the testing of new components, and as such, the industry has moved towards newer, more advanced tester platforms. In moving away from legacy tester platforms, the industry also inadvertently pushes legacy components towards obsolescence, as the testing infrastructure needed for manufacturing is no longer supported or economical to maintain. As new tester platforms are often incompatible with legacy components, this incompatibility creates a significant hurdle for maintaining legacy systems. The inability to test these components effectively can lead to increased risks of failures and reduced reliability<sup>[2]</sup>.</p><h2 dir="ltr" data-element-id="headingsMap-8-0">Advances in Silicon Fabrication Processes</h2><p dir="ltr">In a similar fashion, component obsolescence is often a result of advances in the silicon fabrication processes used for modern components. As semiconductor manufacturers develop more sophisticated and efficient techniques, they introduce new generations of components with enhanced performance, reduced power consumption, and smaller form factors. These new components often lead to the end-of-life (EOL) status for older components because the previous technology cannot compete with the improved capabilities and efficiencies of the new models<sup>[3]</sup>.</p><p dir="ltr">Additionally, as fabrication processes evolve, the equipment and materials required to manufacture older components become less available, increasing production costs and reducing the economic viability of continuing to produce these outdated parts. Manufacturers are more inclined to shift their resources toward producing newer, more profitable components that align with the latest fabrication technologies.</p><p dir="ltr">The impact of these advances extends beyond the components themselves. New silicon fabrication processes often necessitate updates in design software, testing protocols, and even supply chain logistics. Companies must adapt their entire ecosystem to accommodate these changes, further accelerating the EOL status of older components incompatible with the new infrastructure.</p><h2 dir="ltr" data-element-id="headingsMap-9-0">Package Obsolescence&nbsp;</h2><p dir="ltr">Evolution in packaging technology for modern components can often be a driving force in the obsolescence of legacy components<sup>[4]</sup>. As packaging technologies evolve to meet the demands of modern electronics, such as smaller sizes, better thermal management, and greater power capacity, older packages become less viable, eventually phasing out components that rely on these outdated packages.</p><p dir="ltr">Packaging advancements are driven by the need for smaller, more efficient, and higher-performing electronic devices. Modern packaging techniques, such as Ball Grid Array (BGA), Chip Scale Package (CSP), and Wafer Level Package (WLP), offer numerous benefits over older methods like Dual In-line Package (DIP) or Small Outline Integrated Circuit (SOIC). These advanced packages enable higher pin counts, better thermal performance, and improved electrical characteristics, all of which are essential for contemporary high-speed and high-density applications.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE5NDg2ODc1OTM1LXNodXR0ZXJzdG9ja182OTE1NDg1ODMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted">When a new packaging technology is introduced, it often leads to the development of new components designed to take full advantage of the improved performance and miniaturization. This shift renders older packages less attractive, as they cannot match the benefits offered by newer technologies. Consequently, components that rely on older packages become obsolete as demand decreases and manufacturers shift their focus to producing components with modern packaging.</p><p dir="ltr">Moreover, the transition to new packaging technologies can lead to supply chain and manufacturing challenges. Older packaging equipment and materials may become scarce or more expensive to source and maintain, making it economically unfeasible for manufacturers to continue producing components with outdated packages. This economic pressure accelerates the obsolescence of components using older packaging technologies.</p><h2 dir="ltr" data-element-id="headingsMap-10-0">Economic Factors</h2><p dir="ltr">Manufacturers may discontinue the production of no longer profitable components, particularly if demand has shifted to newer technologies<sup>[5]</sup>. Like many others, the aerospace industry is subject to market dynamics that influence the availability of components. As newer, more advanced technologies become prevalent, the demand for older components declines, leading to their obsolescence.</p><p dir="ltr">A notable variable in this equation is the cost inefficiencies associated with producing small quantities of obsolete components, which can be prohibitive for manufacturers. For instance, maintaining production lines for older components requires significant machinery, tooling, and skilled labor investments. These production lines often need specialized equipment and processes tailored to the specific requirements of the legacy components. As these components age, the machinery and tooling needed to produce them may also become obsolete, requiring costly upgrades or replacements.</p><p dir="ltr">Additionally, sourcing raw materials for obsolete components can present significant challenges. Materials used in older manufacturing processes may no longer be readily available, or their supply may have dwindled, driving up costs. Manufacturers must navigate these supply chain complexities, often dealing with higher prices for limited quantities of materials. This situation can further erode the profitability of producing obsolete components.</p><p dir="ltr">Given these economic realities, manufacturers often prioritize the production of components with higher demand and better profit margins. Newer technologies attract larger markets due to their improved performance, enhanced capabilities, and greater efficiency. As a result, manufacturers allocate their resources to developing and producing these advanced components, leaving older technologies behind. This shift in focus accelerates the obsolescence of legacy components as manufacturers gradually phase out their production to concentrate on more lucrative opportunities.</p><h2 dir="ltr" data-element-id="headingsMap-11-0">Conclusion</h2><p dir="ltr">Component obsolescence is a major threat to the preservation of legacy systems. It is important to fully understand its potential causes to best prepare ourselves to handle the challenges arising from it. At Rochester Electronics, we’ve spent decades helping customers navigate the complexities of component obsolescence across all industries. In the next article in this series, we’ll look deeper at the challenges customers encounter when faced with obsolete components.&nbsp;</p><h3 dir="ltr" id="isPasted" data-element-id="headingsMap-12-0">You can learn more about the future-proofing of the aerospace industry by diving into this insightful whitepaper.</h3><h3 data-element-id="headingsMap-13-0">Futureproofing Aerospace Whitepaper Highlights:</h3><ol><li><strong>Understand the Importance of Legacy Systems</strong>: Discover why preserving legacy avionics systems is crucial for reliability, compliance, and cost-effectiveness.</li><li><strong>Navigate Component Obsolescence</strong>: Learn about the challenges aerospace designers face due to outdated or discontinued components and how to address them.</li><li><strong>Explore Solutions from Rochester Electronics</strong>: Gain insights into how Rochester Electronics specializes in preserving and replicating obsolete components to ensure the continued operation of legacy systems.</li></ol><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable fr-active"><iframe src="https://c8056756.sibforms.com/serve/MUIFAI58ML_0Jkq9ohSSVMrlfZ0o5Eup39aCZcy3V6OAZo33jakOcLECU6nQ3NIK9BP2kTGzF7l86SWC2L2j4CzrX7ON60erda6KYq1u3fkfZlqfqvx3n-tgHoSgZUr9MPV6ZCTY28OxdOhn8Fe0Sr2_Je6Hij8GIv-S5GMMYtVvFfZS2Eb2YYUeZ97JSsuW5lvaTW-dqGZytjXp" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block; margin-left: auto; margin-right: auto; max-width: 100%; width: 540px; height: 350px;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h3 dir="ltr" id="isPasted" data-element-id="headingsMap-15-0">You can learn more about the future-proofing of the aerospace industry by diving into our related article series.</h3><p dir="ltr" id="isPasted">Read more in the series:</p><p dir="ltr"><a href="https://www.wevolver.com/article/the-importance-of-preserving-legacy-systems-in-avionics" target="_blank" rel="noopener noreferrer">Article 1: The Importance of Preserving Legacy Systems in Avionics</a></p><p dir="ltr"><a href="https://www.wevolver.com/article/the-causes-of-component-obsolescence" rel="noopener noreferrer" target="_blank">Article 2: The Causes of Component Obsolescence</a></p><p dir="ltr"><a href="https://www.wevolver.com/article/customer-challenges-with-obsolete-components" rel="noopener noreferrer" target="_blank">Article 3: Customer Challenges with Obsolete Components</a></p><p dir="ltr">Article 4: <a href="https://www.wevolver.com/article/solving-obsolescence-with-rochester-electronics" target="_blank" rel="noopener noreferrer">Solving Obsolescence with Rochester Electronics</a></p><p dir="ltr">Article 5: <a href="https://www.wevolver.com/article/proactive-strategies-for-managing-avionics-obsolescence/draft" target="_blank" rel="noopener noreferrer">Proactive Strategies for Managing Avionics Obsolescence</a></p><h2 dir="ltr" data-element-id="headingsMap-16-0">References</h2><ol><li dir="ltr"><p dir="ltr"><a href="https://saemobilus.sae.org/papers/integrated-test-platforms-taking-advantage-advances-computer-hardware-software-2005-01-1044" target="_blank">https://saemobilus.sae.org/papers/integrated-test-platforms-taking-advantage-advances-computer-hardware-software-2005-01-1044</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://ieeexplore.ieee.org/document/7589645" target="_blank">https://ieeexplore.ieee.org/document/7589645</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://ieeexplore.ieee.org/document/5388819/" target="_blank">https://ieeexplore.ieee.org/document/5388819/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://doi.org/10.1088/1742-6596/364/1/012095" target="_blank">https://doi.org/10.1088/1742-6596/364/1/012095</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://pubsonline.informs.org/doi/10.1287/mksc.8.1.35" target="_blank">https://pubsonline.informs.org/doi/10.1287/mksc.8.1.35</a></p></li></ol><p><br></p>

Futureproofing Aerospace Series. Article #2: Understanding the causes of component obsolescence can help us better prepare for it.

The Causes of Component Obsolescence

<table style="width: 100%;"><tbody><tr><td style="width: 100%;"><h2 id="isPasted">Stay at the cutting edge of the aerospace industry</h2><p>We are pleased to have partnered with Rochester Electronics to launch the Future-Proofing Aerospace whitepaper.</p><p>The aerospace industry is continuously evolving, driven by the need to modernize, improve efficiency, and drive down costs. However, as avionics – the electronic systems that power aircraft – continue to advance, the preservation of legacy systems becomes increasingly vital. This whitepaper offers critical insights into the importance of maintaining these systems, the challenges posed by component obsolescence, and the solutions available to navigate these complexities.</p><h3>Whitepaper highlights:</h3><ol><li><strong>Understand the Importance of Legacy Systems</strong>: Discover why preserving legacy avionics systems is crucial for reliability, compliance, and cost-effectiveness.</li><li><strong>Navigate Component Obsolescence</strong>: Learn about the challenges aerospace designers face due to outdated or discontinued components and how to address them.</li><li><strong>Explore Solutions from Rochester Electronics</strong>: Gain insights into how Rochester Electronics specializes in preserving and replicating obsolete components to ensure the continued operation of legacy systems.</li></ol><h3>Download the full paper below:</h3><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable fr-active"><iframe src="https://c8056756.sibforms.com/serve/MUIFAI58ML_0Jkq9ohSSVMrlfZ0o5Eup39aCZcy3V6OAZo33jakOcLECU6nQ3NIK9BP2kTGzF7l86SWC2L2j4CzrX7ON60erda6KYq1u3fkfZlqfqvx3n-tgHoSgZUr9MPV6ZCTY28OxdOhn8Fe0Sr2_Je6Hij8GIv-S5GMMYtVvFfZS2Eb2YYUeZ97JSsuW5lvaTW-dqGZytjXp" frameborder="0" scrolling="auto" allowfullscreen="" style="display: block; margin-left: auto; margin-right: auto; max-width: 100%; width: 540px; height: 350px;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p></td></tr></tbody></table><p dir="ltr" id="isPasted">Like most other transportation fields, the aviation industry is subject to rapid changes and technological advancements. However, unlike other transportation fields, aviation risks are particularly high. Rather than adopting new technologies, avionics designers aim to maintain their existing systems, which have proven themselves safe and reliable after thousands of proven flight hours in real-world conditions.</p><p dir="ltr">But, component obsolescence threatens the continuity of legacy systems. When market forces force a component into obsolescence, short of acceptable 1:1 replacements, engineers are forced to create new designs from scratch. This process incurs significant time, cost, and risk for the avionics designer. &nbsp;&nbsp;</p><p dir="ltr">At Rochester Electronics, we help designers in all industries, including avionics, skirt the challenges of component obsolescence in order to preserve their legacy systems. Read on to learn about the importance of preserving legacy systems in avionics.&nbsp;</p><h1 dir="ltr" id="isPasted">Regulatory Compliance</h1><p dir="ltr">Before any piece of avionics equipment can find itself in production use cases, it must first pass through a stringent series of certifications. Compliance with regulatory standards, such as those set up by the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA), are used to scrutinize the equipment's performance, safety, and reliability under various operational conditions. These standards ensure that every component meets the necessary criteria to function correctly and safely within the complex environment of modern aircraft<sup>[2]</sup>. Naturally, the testing process to achieve certification is complex, time-consuming, and costly<sup>[3]</sup>.&nbsp;</p><p dir="ltr">In the context of component obsolescence and preserving legacy systems, the challenge lies in the fact that even small changes to system designs can render previous certifications obsolete. When design changes are made, compliance bodies view the updated design as effectively an entirely new system, necessitating a recertification. Avionics designers then have to once again engage in the certification process from scratch, entailing huge time and monetary commitments.</p><p dir="ltr">By preserving legacy systems, avionics designers can avoid such changes. Instead of redesigning systems when components become obsolete, replacing those components with acceptable 1:1 alternatives can be achieved, including DO-254 minor change classification, meaning that previous certifications remain intact.&nbsp;</p><h1 dir="ltr">Proven Reliability</h1><p dir="ltr">Even outside of regulatory compliance, avionic systems must undergo extensive performance, lifetime, and reliability testing before they can be deployed in the skies.</p><p dir="ltr">The process of system design validation is an incredibly meticulous one. It commences in the laboratory, where designs are meticulously scrutinized, compared to internal organizational standards, and subjected to the meticulous scrutiny of governing bodies and third-party auditors. This multi-layered approach to validation ensures that when all approvals are met, designers can have high confidence in the quality and reliability of their systems<sup>[4]</sup>. Given the critical nature of aviation systems, this level of testing is non-negotiable, even for seemingly inconsequential systems.</p><p dir="ltr">Following laboratory testing, these systems finally make it to the skies, where they accumulate thousands of real-world flight hours over time. The thousands of flight hours translate directly into a comprehensive understanding of their behavior under diverse conditions and increased confidence in the systems.</p><p dir="ltr">Legacy systems have the benefit of all of this proven reliability behind them. Having experienced intense laboratory testing and then proving themselves in real-world flights, legacy systems offer aviation companies, governing bodies, and passengers the highest guarantee of reliability and safety imaginable. Should component obsolescence necessitate system redesigns, designers can no longer bank on past reliability and must instead send new systems through the same testing and validation processes<sup>[5]</sup>. Replacing obsolete components with new ones disrupts this continuity and undermines confidence in the system.&nbsp;</p><h1 dir="ltr">Cost Efficiency</h1><p dir="ltr">Significant direct and indirect financial costs are associated with replacing legacy systems in favor of new ones<sup>[6]</sup>.</p><p dir="ltr">Directly, the physical process of redesigning systems entails investments in research and development, testing, and certification processes. The engineering hours necessary to succeed in these phases are significant. Once fully designed and through certification, the costs associated with ramping up production of a new design, including supply chain, component sourcing, and physical manufacturing, are also much higher than continuing the production of an existing system.&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4ODA1NTc1MDQxLTI0MDYxMl9KZXNzLTAyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted">Indirectly, &nbsp;new systems often require extensive retraining for maintenance personnel and pilots, further adding to the overall expense. Additionally, integrating new systems into existing aircraft infrastructure often necessitates modifications to other related systems, incurring additional costs.</p><p dir="ltr">By maintaining legacy systems, aerospace companies can avoid these hidden costs and attain a more predictable financial landscape. With well-documented performance and maintenance histories, companies can accurately forecast maintenance costs and plan for parts replacement or system upgrades. In an industry where margins are often thin, and competition is fierce, the ability to efficiently manage resources and maintain proven, reliable systems is a significant advantage.&nbsp;</p><h1 dir="ltr">Interoperability</h1><p dir="ltr">One major challenge when replacing legacy components with modern technology is compatibility.&nbsp;</p><p dir="ltr">Legacy avionics systems, including communication, navigation, and flight control instruments, are often deeply integrated with other aircraft systems and ground infrastructure. New components may not be directly compatible with existing systems in this context, leading to electrical, mechanical, and software integration issues [7]. For instance, new components might operate at different voltages or have different power requirements, necessitating redesigning power supply circuits to provide appropriate voltages and currents. These changes can affect signal integrity and electromagnetic interference (EMI), requiring circuit redesigns to accommodate accordingly.&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4ODA2MDkzNTQ1LXNodXR0ZXJzdG9ja18yMjc0NjI0OTIzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr" id="isPasted">Software compatibility is also a critical factor in the integration process. New components often come with different firmware or drivers that might not be compatible with the existing system's software. Updating the system’s software to support new components can be complex and time-consuming, requiring engineers to rewrite or modify existing code to confirm that the system can control and monitor the new components correctly. This process involves thorough testing and validation to ensure the updated software does not introduce bugs or vulnerabilities that could compromise the system's safety and reliability.</p><p dir="ltr">Maintaining legacy avionics systems helps to avoid these compatibility issues and the associated costs and risks. By preserving the established integration between avionics and other aircraft systems, operators can ensure that all components continue to function as intended, maintaining safety, reliability, and efficiency. &nbsp;</p><h1 dir="ltr">Technical Expertise</h1><p dir="ltr">Finally, there is significant value to the cumulative years of experience that maintenance personnel and pilots have garnered with legacy systems. Over many hundreds of hours of direct, hands-on experience with a specific legacy solution, these individuals develop a deep and expert understanding of the systems at play, giving them more confidence in their abilities and allowing for more effective troubleshooting and repairs in the event of an issue.</p><p dir="ltr">The transition to new avionics systems is not a straightforward process when components become obsolete and new systems are introduced<sup>[7]</sup>. It necessitates extensive retraining for maintenance personnel and pilots, a process that is both time-consuming and costly. Maintenance crews must learn the intricacies of the new systems, including diagnostics, repair procedures, and potential integration issues with existing aircraft infrastructure. Pilots need to become familiar with new interfaces, operational procedures, and any changes in system behavior. Importantly, the retraining period can lead to a temporary reduction in operational efficiency as personnel adjust to the new systems, potentially impacting day-to-day operations.</p><p dir="ltr">By maintaining the continuity of legacy systems, avionics designers can maintain the expertise of maintenance crew and pilots. This means smoother aircraft operation, higher degree of safety, decreased downtime in the event of repairs, and overall more efficient operations. &nbsp;</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">Preserving legacy avionics systems has many benefits, yet component obsolescence consistently threatens their continuity. Rochester Electronics has decades of experience addressing these threats head-on, helping customers preserve their systems and harness all of the benefits that follow. In the next article in this series, we will explore the causes of component obsolescence in greater detail.</p><p dir="ltr">For even more technical detail and detailed case studies, download our recently released whitepaper.&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE4ODA2NjQzNjIzLXJvY2hlc3RlciBtb2NrdXAzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"></p><h3>Whitepaper highlights:</h3><ol><li><strong>Understand the Importance of Legacy Systems</strong>: Discover why preserving legacy avionics systems is crucial for reliability, compliance, and cost-effectiveness.</li><li><strong>Navigate Component Obsolescence</strong>: Learn about the challenges aerospace designers face due to outdated or discontinued components and how to address them.</li><li><strong>Explore Solutions from Rochester Electronics</strong>: Gain insights into how Rochester Electronics specializes in preserving and replicating obsolete components to ensure the continued operation of legacy systems.</li></ol><h3>Read more in the series:</h3><p dir="ltr" id="isPasted">Read more in the series:</p><p dir="ltr"><a href="http://the%20importance%20of%20preserving%20legacy%20systems%20in%20avionics/" target="_blank" rel="nofollow">Article 1: The Importance of Preserving Legacy Systems in Avionics</a></p><p dir="ltr"><a href="https://www.wevolver.com/article/the-causes-of-component-obsolescence" rel="noopener noreferrer" target="_blank">Article 2: The Causes of Component Obsolescence</a></p><p dir="ltr"><a href="https://www.wevolver.com/article/customer-challenges-with-obsolete-components" rel="noopener noreferrer" target="_blank">Article 3: Customer Challenges with Obsolete Components</a></p><p dir="ltr">Article 4: <a href="https://www.wevolver.com/article/solving-obsolescence-with-rochester-electronics" target="_blank" rel="noopener noreferrer">Solving Obsolescence with Rochester Electronics</a></p><p dir="ltr">Article 5: <a href="https://www.wevolver.com/article/proactive-strategies-for-managing-avionics-obsolescence/draft" target="_blank" rel="noopener noreferrer">Proactive Strategies for Managing Avionics Obsolescence</a></p><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr"><a href="https://resources.pcb.cadence.com/blog/component-obsolescence-drives-legacy-maintenance-costs" target="_blank">https://resources.pcb.cadence.com/blog/component-obsolescence-drives-legacy-maintenance-costs</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://ieeexplore.ieee.org/document/1390796" target="_blank">https://ieeexplore.ieee.org/document/1390796</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://ieeexplore.ieee.org/document/949469" target="_blank">https://ieeexplore.ieee.org/document/949469</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://nbaa.org/news/business-aviation-insider/2022-05/third-party-audits-validate-safety-processes/" target="_blank" rel="noopener noreferrer">https://nbaa.org/news/business-aviation-insider/2022-05/third-party-audits-validate-safety-processes/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://ieeexplore.ieee.org/document/10311235/" target="_blank">https://ieeexplore.ieee.org/document/10311235/</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://onlinelibrary.wiley.com/doi/10.1111/j.1559-3584.2010.00263.x" target="_blank">https://onlinelibrary.wiley.com/doi/10.1111/j.1559-3584.2010.00263.x</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://ieeexplore.ieee.org/document/9081621" target="_blank">https://ieeexplore.ieee.org/document/9081621</a></p></li><li dir="ltr"><p dir="ltr"><a href="https://journals.sagepub.com/doi/10.1177/107118137702100105" target="_blank">https://journals.sagepub.com/doi/10.1177/107118137702100105</a></p></li></ol>

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