<p dir="ltr" id="isPasted">As aerospace and defense projects grow in complexity, the industry faces a need for new methodologies to manage complex system architectures and facilitate design validation processes. Model-Based Systems Engineering (MBSE) is addressing these challenges by moving organizations from document-based systems to a model-centric approach.&nbsp;</p><p dir="ltr">One key player driving this transformation is Quest Global, a leading engineering services provider renowned for its pioneering role in digital thread integration across the aerospace and defense industry. Quest Global has established itself as a trusted partner, helping major aerospace organizations adopt Model-Based Systems Engineering (MBSE) and leverage digital thread solutions to enhance project efficiency, system accuracy, and cross-functional collaboration. Their expertise in integrating MBSE techniques has enabled aerospace companies to meet modern challenges head-on, significantly improving project outcomes.</p><p dir="ltr">This article explores how MBSE connects design processes and tools to enable greater flexibility, accuracy, and efficiency in aerospace and defense projects. It also highlights Quest Global's role in leading this transformation, providing case studies on successful implementation to illustrate its real-world applications and benefits across all development stages.</p><h2 dir="ltr" data-element-id="headingsMap-4-0">Why the Shift from Document-Based to Model-Based Systems Engineering?</h2><p dir="ltr">MBSE is a systems engineering methodology that fundamentally improves how complex systems are developed and managed throughout their entire lifecycle. At its core, MBSE allows for an authoritative source of truth (ASoT) for systems, depicting components as interconnected blocks with defined boundaries and interfaces. This visual representation aids both technical and non-technical stakeholders in understanding complex systems. For example, in developing a new turbofan engine, MBSE can map interactions between the engine and external systems like avionics and flight controls.</p><p dir="ltr">One of the key features of MBSE is its centralized model-based approach. In MBSE, a well-structured model provides a graphical representation of processes, structures, and workflows, making it easier to understand and manage. In this approach, changes made within a model propagate automatically, ensuring consistency and reducing labor.</p><h2 id="isPasted" data-element-id="headingsMap-5-0">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h2><p dir="ltr" id="isPasted">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr" data-element-id="headingsMap-7-0">Benefits of MBSE in Aerospace</h2><p dir="ltr">Model-Based Systems Engineering (MBSE) significantly enhances efficiency by streamlining the development process, leading to reduced time to market and faster product launches. This approach also contributes to substantial cost reductions by leveraging models effectively to identify and address inefficiencies early in the development cycle.</p><p dir="ltr">A core objective of MBSE is to improve product quality by enhancing system design and reducing defects. Executives can monitor this improvement through key metrics, such as defect rates and performance indicators, reflecting the quality of systems engineering outputs. Additionally, MBSE fosters stakeholder satisfaction through improved communication and collaboration across teams.&nbsp;</p><p dir="ltr">Assessing the return on investment (ROI) of MBSE is crucial for understanding its financial impact. Executives should evaluate cost savings from reduced errors, increased productivity from streamlined processes, and improved product quality that leads to better market performance. Furthermore, it is essential for MBSE initiatives to align with the organization’s strategic goals. Evaluating the extent to which MBSE contributes to long-term success ensures that it serves as a strategic enabler, supporting the organization's vision and mission.</p><h2 dir="ltr" data-element-id="headingsMap-8-0">From Complexity to Clarity: Streamlining Aerospace Design with MBSE</h2><p dir="ltr">The use of a digital modeling approach significantly enhances system architecture in aerospace projects, offering improved visualization and analysis. Digital models provide a clear and cohesive representation of complex systems, enabling engineering teams to better understand and navigate the intricacies of the design architecture.</p><p dir="ltr">Quest Defense (QDSS), the US subsidiary of Quest Global, has been instrumental in helping its clients navigate the complexities of MBSE implementation. Recent projects have demonstrated Quest Defense's capability to streamline systems engineering processes and deliver tangible ROI for its clients.</p><p dir="ltr">A prime example of this is the F-35 program, in which QDSS was a key partner. Despite its success, the F-35 program initially faced numerous challenges, including significant budget overruns and delays. Some of the key challenges included maintaining and evolving unified systems engineering artifacts, traceability, communications, incomplete validation and verification requirements, as well as not reusing systems developed in earlier programs.&nbsp;</p><p dir="ltr">Learning from past challenges, the Department of Defense (DOD) has issued a mandate to build a systems engineering infrastructure using MBSE to address the shortcomings of classical systems engineering methods. MBSE artifacts serve as the Authoritative Source of Truth (ASoT), ensuring consistency throughout the program, reducing the risk of systems architecture divergence, better documenting V&amp;V requirements, and improving communication. Additionally, MBSE facilitates the creation of reusable models for future development, borrowing principles from object-oriented software design. The F-35 was therefore developed as an entirely bespoke effort, with everything built from the ground up. This approach highlighted the need for a more efficient system. This approach allowed for the incorporation of reusable components into new projects, thereby decreasing development time, costs, and risks.</p><p dir="ltr">With QDSS’ support, the Original Equipment Manufacturer (OEM) experienced accelerated project timelines, significant reductions in design and development costs, and improved system strategies and architectures. QDSS’ digital thread integration enabled a streamlined flow of data across the entire development process, enhancing system traceability and ensuring real-time updates in response to design changes.</p><h2 dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMwMjkxNDM5Njg3LXNodXR0ZXJzdG9ja18yMjQwNzk1NTQxLmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></h2><h2 dir="ltr" data-element-id="headingsMap-10-0">MBSE’s Strategic Edge in Aerospace and Defense Engineering</h2><p dir="ltr">The success of the F-35 program highlights the many benefits of adopting a MBSE approach for aerospace and defense manufacturing. Some other key advantages include:&nbsp;</p><ul><li dir="ltr"><p dir="ltr"><strong>Enhanced Traceability and Consistency:</strong> MBSE ensures that all changes are automatically updated throughout the system, maintaining consistency and reducing manual effort.</p></li><li dir="ltr"><p dir="ltr"><strong>Improved Communication:</strong> The graphical nature of MBSE models facilitates better communication among stakeholders, including non-technical personnel, by providing clear visualizations of system interactions.</p></li><li dir="ltr"><p dir="ltr"><strong>Reuse of Models:</strong> Models can be stored in libraries and reused in future projects, significantly reducing development time and costs. This is particularly beneficial in A&amp;D, where similar components like turbines or engines can be repurposed with minimal modifications.</p></li><li dir="ltr"><p dir="ltr"><strong>Reduced Risk of Overruns</strong>:&nbsp;MBSE provides a clear and consistent roadmap that mitigates risks associated with budget overruns and project delays.</p></li><li dir="ltr"><p dir="ltr"><strong>Seamless Independent Validation and Verification:</strong> Independent Validation &amp; Verification (IV&amp;V) is critical to any systems engineering process. Validation ensures that the correct system is being built according to requirements (validating against the CONOPS), while Verification ensures that the system is being built correctly (meeting the requirements). MBSE supports IV&amp;V by mapping these cases both graphically and tabularly, creating clear linkages between requirements, validation, and verification. This reduces errors and simplifies the verification process to ensure the system works and that test cases are included in the model.</p></li></ul><h2 dir="ltr" data-element-id="headingsMap-11-0">Addressing MBSE Implementation Issues</h2><p dir="ltr">Transitioning to MBSE is not without its challenges. Organizations often face resistance due to the significant paradigm shift required. Key challenges include:&nbsp;</p><ul><li dir="ltr"><p dir="ltr"><strong>Organizational Buy-In:</strong> Senior management must be convinced of MBSE's benefits, necessitating a top-down approach to implementation.</p></li><li dir="ltr"><p dir="ltr"><strong>Training and Education</strong>:&nbsp;Employees need to learn a new vocabulary and syntax, transitioning from text-based documentation to graphical models. Comprehensive training is essential to facilitate this shift.</p></li><li dir="ltr"><p dir="ltr"><strong>Infrastructure and Tools:</strong> Implementing MBSE requires substantial investment in tools and IT infrastructure. Tools like Cameo can be expensive, and setting up the necessary back-end support involves additional costs.</p></li><li dir="ltr"><p dir="ltr"><strong>Cultural Resistance:</strong> There is often resistance from experienced personnel accustomed to traditional methods. Younger employees may adapt more readily, but older staff may see little value in changing established practices.</p></li></ul><h2 dir="ltr" data-element-id="headingsMap-12-0">Navigating MBSE Hurdles in Complex Engineering Projects</h2><p dir="ltr">In order to ensure a successful MBSE implementation, A&amp;D organizations can take several steps and consult partners like Quest Global to facilitate a smooth transition through the following strategies:</p><ul><li dir="ltr"><p dir="ltr"><strong>Develop Systems Engineering Fundamentals:</strong> Establishing a solid systems engineering process is crucial before transitioning to MBSE. This includes developing a requirements definition and management process, configuration management, and validation and verification methods.</p></li><li dir="ltr"><p dir="ltr"><strong>Evangelize MBSE Benefits</strong>: Clearly communicate the advantages of MBSE to all stakeholders, emphasizing improved efficiency, traceability, and reduced risk. Projects using an MBSE approach cost 55% less than projects using a traditional SE approach. In addition, projects using an MBSE approach delivered on time 62% of the time, compared to 59% of the time with a traditional SE approach, and up to 70% of defects have been identified during the modeling and simulation stage.</p></li><li dir="ltr"><p dir="ltr"><strong>Provide Comprehensive Training:</strong> Invest in training programs to help employees understand and adopt MBSE practices.</p></li><li dir="ltr"><p dir="ltr"><strong>Invest in the Right Tools:</strong> Carefully select and invest in MBSE tools and infrastructure, ensuring compatibility and scalability for future projects.</p></li><li dir="ltr"><p dir="ltr"><strong>Build a Culture of Continuous Improvement:&nbsp;</strong>Encourage a culture that values continuous improvement and adaptation to new methodologies. This includes fostering collaboration and open communication among all team members.</p></li></ul><h2 dir="ltr" data-element-id="headingsMap-13-0">Facilitating MBSE Adoption In Aerospace and Defense</h2><p dir="ltr">The future of MBSE in the A&amp;D sector looks promising, with increasing mandates for its adoption to avoid past pitfalls and improve project outcomes. Quest Global expertise in implementing systems engineering processes extends beyond just technical implementation. They work closely with clients to address organizational and cultural challenges, providing comprehensive training and support to ensure seamless integration of Model-Based Systems Engineering (MBSE) and digital threads. As organizations continue to recognize the benefits of MBSE, its implementation will become more widespread, leading to more efficient and effective systems engineering processes.</p><h3 dir="ltr" id="isPasted" data-element-id="headingsMap-14-0">References</h3><p dir="ltr">1. Systematic Literature Review: How is Model Based Systems Engineering Justified? Edward R. Carroll and Robert J. Malins, SANDIA REPORT SAND2016- 2607 Unlimited Release March 2016.</p>

Explore how MBSE can be used to optimize system architecture, streamline design validation, and facilitate collaboration in aerospace projects.

From Documents to Models: Improving System Architecture and  Design Validation in Aerospace With Model-Based Systems Engineering (MBSE)

<p dir="ltr" id="isPasted">Space deployment comes with a series of significant engineering challenges for the electronic and electrical systems that are going to be utilised. Engineers must therefore specify components for their designs that have all the necessary properties – particularly in relation to coping with the harsh environments they are going to be situated in, alongside the acute size, weight and power (SWAP) constraints involved. In this article, we will look at exactly what this will entail and give a detailed use case example to illustrate the points raised too.</p><h2 dir="ltr">Unique aspects of the application setting</h2><p dir="ltr">Though this must still be adequately addressed, it is not actually space itself that poses the biggest threat to component reliability. Instead, it is the process of getting it there that is likely to be the problematic part. During launch, a rocket’s payload can easily be subjected to 4-5g accelerations. On top of that, there are certain to be intense vibrational forces experienced. There is the potential for hardware to be exposed to very high levels of heat too. Should any damage occur at this stage, then the space deployed equipment might not be able to carry out its assigned functions as intended and the mission will end up being a failure.&nbsp;</p><p dir="ltr">Once the hardware is finally in orbit, there will be other considerations. Among the most prominent is the temperature cycling that components will have to deal with – going from severe cold when traversing the dark side of the Earth, followed by periods in the Sun’s harsh thermal radiation. Another consideration is whether the chosen components will be detrimentally affected by the vacuum of space. Outgassing means that chemical substances could be emitted from these components, due to seepage from cracks or internal gaps. This might result in delicate instrumentation in close proximity to them being impaired in some way by the presence of unwanted contaminants. Once again, the mission could be jeopardised, meaning that all the expense and engineering effort that had gone into it would count for nothing. &nbsp;&nbsp;</p><h2 dir="ltr">Sourcing interconnects for space&nbsp;</h2><p dir="ltr">The various factors just described make it very clear that the connectors and cabling being selected for space deployment must have superior operational characteristics. Consequently, it is vital that they are able to withstand prolonged mechanical stresses (in terms of both shock and vibration), as well as extreme temperatures. The remote nature of the application of course means that once deployed there is no opportunity to replace faulty interconnects. This is why chances cannot be taken on choosing anything other than a solution with the highest degrees of reliability and resilience to the most challenging of ambient environments.</p><p dir="ltr">Having collaborated on a multitude of different projects in this sector over several decades, Harwin offers an extensive portfolio of space-qualified connectors and cables. Each of these has a heavy duty construction, so that prolonged reliability is assured. They can be provided with built-in shielding (both backshells and braids) to protect them from cosmic radiation.</p><h3 dir="ltr">Use case example</h3><p dir="ltr">A recent venture, on which Harwin worked with the Group of Astrodynamics for the Use of Space Systems&nbsp;(GAUSS), underlines the need for sourcing appropriate connectors and cabling. GAUSS is an established provider of microsatellite deployment solutions, as well as designing and manufacturing its own satellite hardware. The Italian company’s UNISAT platform enables the in-orbit-release of third-party pico/nano-satellites, with numerous CubeSats and PocketQubes being carried into space on each mission and then getting deployed directly from a purpose-built spacecraft. This approach has made it much more convenient and cost-effective for academic research groups to undertake space-based experiments and monitoring work, as they can reduce the upfront expense normally associated with ‘rideshare’ activities.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729852467851-wendy-1.jpg" style="width: 832px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 1: The UNISAT-7 pico/nano-satellite deployment platform from GAUSS (images courtesy of Gauss Srl)</span></span></span></p><p dir="ltr">When the GAUSS team embarked upon the development of their latest UNISAT spacecraft, there were some key objectives that they wanted to achieve. The most important of these was to be able to expand the payload capacity. This would mean that a greater quantity of CubeSats and PocketQubes could be deployed. The engineering team at GAUSS looked at ways that they could make UNISAT-7 construction more lightweight than the previous models, so more of the assigned launch mass could be taken up by the payload.&nbsp;</p><p dir="ltr">For it to be accommodated in the rocket, the UNISAT-7 spacecraft’s overall volume had to be kept as low as possible. Its total launch mass had to be kept down to no more than 32kg. All of the constituent electronics would be contained within an aerospace-grade aluminium honeycomb framework of 50mm x 50mm x 50mm dimensions. This would have carbon fibre sheets attached to it. The spacecraft’s power would be generated by banks of photovoltaic panels mounted onto its exterior.&nbsp;</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729852521555-wendy+3.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 2: View of rocket used to deploy multiple satellites (image courtesy of GK Launch Services)</span></span></span></p><p dir="ltr">Given that the UNISAT-7 needed to remain operational for up to 5 years, the ongoing integrity of the interconnect technology had to be beyond doubt. After sampling and testing connectors from a variety of different manufacturers, GAUSS engineers decided that going with units featured in the Harwin Datamate series would be the best tactic. Datamate and Datamate Mix-Tek connectors have shown themselves to be very effective when used in spaceborne equipment. These high-reliability (Hi-Rel) components are robust enough to cope with the difficult conditions posed by space launches. They can withstand 20G vibrations and 100G shocks, plus up to 125°C temperature levels. Their compact form factor means that they take up only minimal board space, leaving plenty of room for other devices.</p><p>The 4-finger Beryllium Copper contacts incorporated into Harwin Datamate connectors allow them to always maintain a connection with their corresponding mating surfaces. The contacts in a standard Datamate mating pair carry up to 3A of current, while Datamate Mix-Tek contacts are 40A rated. The advanced locking features employed mean that industry-leading interconnect retention is attained.</p><p>The low outgassing that these connectors exhibit is another important benefit. For instance, the moulded plastic used in them has a 1.01% total mass loss (TML) and a collected volatile condensable material (CVCM) figure of less than 0.01% when placed in the vacuum of space.</p><p dir="ltr">Complementing their low profile, the availability of right-angle configuration Datamate versions addresses limited gaps between PCBs in space hardware designs. It means that connectors can be positioned at the edge of these PCBs, thereby avoiding the need for cabling to reach further into these boards. The upshot is that cables and connectors are much easier to access when the hardware is being assembled. Furthermore, cables do not need to be bent to such great angles – with less chance of them breaking in the process. &nbsp;</p><p>Having been successfully trialled out by GAUSS, the selected Harwin connectors would play an integral role in the communication and data processing elements of the UNISAT-7, allowing all the related data to be transported. They would also prove essential to the spacecraft’s power systems.&nbsp;</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729852579004-wendy+4.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Figure 3: Connectors visible in the PCB stack of a small satellite (image courtesy of Gauss Srl)</span></span></span></p><h2>Conclusion</h2><p dir="ltr">Space hardware must be able to rely on the quality of interconnect technology that has been specified for it. Any cutting of corners here could lead to projects that may have taken years to prepare for and large amounts of money to fund falling short of the goals that they were originally set and not meeting expectations. That is why engaging with an expert in this area is definitely advised. This will mean the connectors and cabling can be recommended that are fully optimised for such purposes.</p>

Space deployment presents significant engineering challenges for electronic and electrical systems, requiring engineers to specify components with properties suited to harsh environments and acute size, weight, and power (SWAP) constraints.

Implementing Effective Interconnects into Space System Designs

<p dir="ltr" id="isPasted">The rapid technological advancements present huge challenges to the Defense &amp; Aerospace industry. As the demand for innovations rises, companies are under considerable strain to deliver advanced technologies while navigating strict timelines. Moreover, the increasing complexity of aerospace systems has made managing design, production, and operational challenges more critical than ever.</p><p dir="ltr">Companies adjust their procedures to ensure efficient and effective project execution for rising complexities and smooth system integration. Simultaneously, the industry is grappling with growing regulatory and cost pressures, as there is a heightened emphasis on reducing development times, to meet the rapidly evolving customer needs, while meeting defense and safety requirements. This balance between innovation and financial restrictions has become the industry's hallmark.</p><h2 id="isPasted">Watch It On-Demand: Unlocking the Power of Digital Twins for Aerospace Manufacturing</h2><p dir="ltr">Now available on-demand, <strong>“Unlocking the Power of Digital Twins for Aerospace Manufacturing”</strong> provides valuable insights into how these transformative technologies are reshaping the industry. Access now:</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p><h2 dir="ltr">Challenges Faced by the Defense &amp; Aerospace Industry</h2><p dir="ltr">Defense &amp; Aerospace programs often face the daunting task of delivering every more sophisticated systems at reduced cost and time. This demand to reduce costs and accelerate development cycles while maintaining the highest standards of quality and performance is a significant hurdle for companies operating in this sector.</p><p dir="ltr">In addition to these challenges, integrating new technologies into existing systems adds still another degree of difficulty. Companies have to incorporate these innovations while guaranteeing compatibility and best performance across all components.<sup>[1]</sup> This is further compounded by the need to manage and coordinate large, multi-functional teams, often spread across different locations and disciplines.</p><p dir="ltr">Moreover, legacy systems and outdated processes often hinder many organizations. These limitations can impede the adoption of modern digital engineering practices, which are crucial for staying competitive in today's fast-paced environment. Also, there is a growing need for real-time, accurate data throughout the product lifecycle, from design to operation, to enable data-driven decision-making and optimize performance.</p><h2 dir="ltr">Digital Solutions in Aerospace Engineering</h2><p dir="ltr">To counter the challenges discussed above, Defense &amp; Aerospace companies are increasingly turning to more integrated and digitalized product design and development solutions to. One such approach is implementing an integrated digital thread, which enable uninterrupted information flow throughout the concept, design, production, and operational stages. By creating a cohesive digital ecosystem, Defense &amp; Aerospace companies can improve collaboration, optimize processes, reduce rework and maintain data consistency across the entire product lifecycle.</p><h3 dir="ltr">Model-Based Systems Engineering (MBSE)</h3><p>Model-Based Systems Engineering (MBSE) is a powerful tool for managing the complexity of modern aerospace systems. By leveraging MBSE, engineers can create extended digital models that integrate various subsystems and components, allowing for efficient system design, simulation, and validation. This approach emphasizes using models as a central means of communication, analysis, and decision-making throughout the product lifecycle to detect potential issues early, reduce the need for physical prototypes, and facilitate better decision-making throughout development processes.<sup>[2]</sup> Additionally, MBSE facilitates collaboration among various stakeholders, assuring everyone works towards a shared understanding of the system's requirements and design.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5NTk4NDg3NDU1LWZvdXIgcXVhZHJhbnRzIG9mIHRoZSBNQlNFIG1vZGVsLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">The four quadrants of the MBSE model process of system development from conceptualization to realization. Image credit:&nbsp;<a href="https://protect.checkpoint.com/v2/___https://insights.sei.cmu.edu/blog/introduction-model-based-systems-engineering-mbse/___.YzJ1OnF1ZXN0Z2xvYmFsOmM6bzoxNjJiNGNiOTM2NDJlYjYzZDA2YWFmMjBjZDYyMDdiNzo2OmVlMjk6YmY1MjllYjdmOWI5NWNjYjU0YzQwZjhjODMwYTJkMzEyMzVhZjBhN2MyZDU2OTQ3NWM4YTE5MjRjMGM3YzZkMDpwOlQ6Tg" target="_blank" rel="noopener noreferrer">Carnegie Mellon University.</a></span></span></span></p><h3 dir="ltr" id="isPasted">Digital Twins</h3><p dir="ltr">Digital twins—virtual replicas of physical systems are modifying how aerospace companies approach predictive analytics, optimization, and lifecycle management. By continuously collecting and analyzing data from sensors embedded in aircraft and other aerospace systems, digital twins provide real-time insights into system performance, facilitating proactive maintenance, improved efficiency, and heightened safety.<sup>[3]</sup> Digital twins also provide virtual testing and simulation, reducing the need for costly physical tests, hence accelerating the development approach.</p><h3 dir="ltr">Automation and Parametric Modelling</h3><p dir="ltr">Using automation tools is also a crucial digital solution, such as parametric modeling, which is essential in speeding up the design processes and optimizing performance in the aerospace industry. By altering parameters, designers can quickly explore various design options without having to start from scratch each time. It enables rapid prototyping and iteration, leading to the identification of optimal solutions and reduced time to market.</p><h3 dir="ltr">Advanced Manufacturing and Supply Chain</h3><p dir="ltr">The manufacturing sector is seeing a substantial transition with the use of Industry 4.0 technologies, including the Internet of Things (IIoT), big data analytics, and automation. These technologies facilitate the establishment of intelligent factories, wherein machines are outfitted with sensors that gather real-time data, thereby enabling communication between machines and between machines and humans. This data can be analyzed to predict and prevent equipment failures, optimize processes, and improve overall efficiency.</p><p dir="ltr">Augmented Reality (AR) is another key technology in Industry 4.0, bridging the gap between the physical and digital experiencs. AR enables technicians and engineers to access real-time information about complex machinery and equipment through wearable devices or mobile apps, thereby reducing the dependence on cumbersome manuals. The implementation of AR can significantly reduce installation and maintenance time, minimize errors and rework, and improve safety of the factory floor.</p><p dir="ltr">Quest Global is driving digital transformation in the manufacturing industry, providing solutions like <a href="https://www.quest-global.com/solutions/ar360/">Quest Global AR360</a>. This platform helps companies develop, deploy, and manage AR applications for various industries, enabling them to reinvent training content, improve classroom experiences, and reduce dependency on field machines. By leveraging AR and other Industry 4.0 technologies, manufacturers can increase production, reduce costs, and improve overall efficiency, positioning for success in the era of smart manufacturing.</p><h3 dir="ltr">Cross-Industry Best Practices</h3><p dir="ltr">Aerospace companies are also increasingly looking to adjacent industries, such as automotive and defense, to learn from their digital transformation experiences and adopt best practices to facilitate their digital journey.<sup>[4]</sup></p><h2 dir="ltr">Case Study: Digital Engineering for UK Defense (Project Agnostics)</h2><p dir="ltr">Quest Global is a leading global engineering services provider at the forefront of driving digital transformation in the Defense &amp; Aerospace industry. One such example is Quest Global's collaboration with a leading aerospace and defense company to support the Future Combat Air System (FCAS) development for the UK Ministry of Defense (MoD). The FCAS program aimed to deliver a next-generation air defense system that would ensure the UK's air superiority for decades to come.</p><p dir="ltr">The FCAS project also faced several other key challenges, including tight timeframes, budget restrictions, and the inherent complexity of developing a state-of-the-art defense system at "half time and half cost." Additionally, integrating advanced digital engineering tools was important to ensure collaboration and efficient project execution.</p><p dir="ltr">Quest Global and its partner therefore created a digital engineering solution designed to address these challenges. It advanced the project by contributing as a thought leader and implementation catalyst. The team is collaborating with the customer to discover how digital technologies may improve procedures, lower costs, and speed up development.</p><p dir="ltr">To ensure the successful implementation of this digital engineering approach, Quest Global deployed a cross-functional team of 25 highly skilled engineers. This team combined expertise from across industries, including aerospace and defense, to create a robust and innovative digital engineering environment. The team significantly reduced project timelines and improved efficiency across the board by using advanced digital tools and best practices.</p><p dir="ltr">Quest Global's approach to digital engineering, which combines deep domain expertise with cross-industry best practices, is expected to be a key differentiator in the success of the FCAS project. The company's thought leadership and innovative solutions, tailored to the specific needs of the client, aim to deliver tangible results in terms of cost reduction and timeline acceleration.</p><p dir="ltr">By working towards the goal of reducing costs without compromising quality, Quest Global is demonstrating the potential of digital technologies to transform the aerospace industry. If successful, the substantial reduction in project development times could set a new standard for efficiency in the sector, paving the way for faster, more agile development processes in the future.</p><h2 dir="ltr">Conclusion: Future Directions for Aerospace Engineering</h2><p dir="ltr">As the aerospace industry evolves, it is expected to increasingly adopt digital thread technologies, which enable easy integration and flow of data across the entire product lifecycle. The digital threads will be necessary for simplifying real-time monitoring, predictive maintenance, and enhanced lifecycle management of aerospace products. By using the digital threads, organizations can achieve improved efficiency, safety, and performance.</p><p dir="ltr">Looking ahead, the emphasis on cost and time reduction will remain a top priority for the aerospace industry, particularly in the defense sector.<sup>[5]</sup> Future projects will focus on delivering highly sophisticated systems within ever-tightening timeframes, driving the need for even more advanced digital engineering solutions and agile development methodologies.</p><p dir="ltr">The success of aerospace companies will be increasingly dependent on their capacity to acquire collaborative digital ecosystems. Organizations can accelerate decision-making, enhance innovation, and dismantle silos by establishing environments in which data circulates effectively across functions and teams. This shift towards increased collaboration and data-driven insights will be essential in addressing the numerous challenges faced by the aerospace industry.</p><h2 dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" 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></h2><h2 dir="ltr" id="isPasted">References</h2><p dir="ltr">1. Terrile RJ. Pathways and challenges to innovation in aerospace. In2010 IEEE Aerospace Conference 2010 Mar 6 (pp. 1-7). IEEE. (Accessed on September 20, 2024)</p><p dir="ltr">2. Uckun S, Kurtoglu T, Bunus P, Tumer I, Hoyle C, Musliner D. Model-based systems engineering for the design and development of complex aerospace systems. SAE Technical Paper; 2011 Oct 18. (Accessed on September 20, 2024)</p><p dir="ltr">3. Xiong M, Wang H. Digital twin applications in aviation industry: A review. The International Journal of Advanced Manufacturing Technology. 2022 Aug;121(9):5677-92. (Accessed on September 21, 2024)</p><p dir="ltr">4. Thompson R, Patel S. Cross-industry learning: Best practices from automotive to aerospace. J Eng Manag. 2022;35(3):245-60. (Accessed on September 23, 2024)</p><p dir="ltr">5. Patel, Jay. Future of Aerospace Industry with Opportunities and Challenges. 10.13140/RG.2.2.16721.51049. (Accessed on September 23, 2024)</p>

Defense & Aerospace companies are turning to digital engineering solutions to deliver advanced technologies while meeting strict timelines and budgets.

Addressing Challenges in the Defense & Aerospace Industry with Digital Engineering Solutions

<div data-message-author-role="assistant" data-message-id="678dcb21-279e-4b73-b592-a9c0fa9c4417" dir="auto" data-message-model-slug="gpt-4o" id="isPasted"><p>The aerospace industry faces growing challenges, from managing complex supply chains and rising operational costs to meeting stringent regulatory demands—all while striving for greater safety, efficiency, and cost reduction. Traditional methods are falling behind, resulting in lengthy design cycles, costly prototyping, and interoperability issues. To stay competitive, companies are increasingly adopting digital twin and digital thread technologies to drive innovation and operational excellence.&nbsp;</p><p>In the webinar "<strong>Unlocking the Power of Digital Twins for Aerospace Manufacturing,</strong>" Quest Global, with over two decades of experience in digital transformation of both aerospace and defense manufacturing, shared expert insights on how these technologies are transforming the industry. If you couldn’t attend the live webinar, you don’t have to miss out. &nbsp;Access the on-demand recording of the webinar now:</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe id="JotFormIFrame-243541854347461" title="Quest Global Form Post-Webinar 1 [Send video]" allowtransparency="true" src="https://form.jotform.com/243541854347461" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe></span></p></div><h3 dir="ltr">Leading the Transformation in Aerospace Innovation: How Quest Global is Revolutionizing Aerospace with Scalable Digital Solutions</h3><p dir="ltr">Spearheading this digital transformation across two decades, Quest Global has a proven track-record of successful implementation of scalable digital solutions in the aerospace and defense industry. In this webinar Head of Engineering, Nick Charles and Head of Advanced Manufacturing CoE Vijay Anand, from Quest Global will sit down with tech writer Samir Jaber to unpack how aerospace manufacturers and Original Equipment Manufacturers (OEMs) are leveraging digital twin technology and digital threads to enhance operational efficiency.</p><h3 dir="ltr">Who should watch this webinar?</h3><p dir="ltr">This webinar is designed to provide <strong>aerospace engineers, manufacturing professionals,</strong> and <strong>decision-makers</strong> looking to optimize their production processes with actionable insights into the transformative power of digital twins. By attending, you'll gain practical knowledge on using digital twin technology to boost efficiency, reduce costs, and improve overall aerospace operations, making it a must-attend event for those looking to stay competitive in the industry.</p><h3 dir="ltr">Why you should watch it:</h3><ul><li dir="ltr"><p dir="ltr"><strong>Learn Cutting-Edge Techniques:&nbsp;</strong>Discover how digital twins can transform aerospace manufacturing by reducing non-conformance, improving process efficiency, and optimizing designs with predictive analytics.</p></li><li dir="ltr"><p dir="ltr"><strong>Enhance Decision-Making:</strong> Understand how integrating digital twins into aerospace supply chains enables real-time decision-making for better outcomes and reduced downtime.</p></li><li dir="ltr"><p dir="ltr"><strong>Gain Competitive Advantage:</strong> Stay ahead by learning to leverage digital twins to streamline operations, boost productivity, and drive innovation in the aerospace industry.</p></li></ul><h2 dir="ltr">Explore more details of the webinar below:</h2><p dir="ltr">This webinar will cover how digital twins and digital threads are revolutionizing aerospace manufacturing by bridging the gap between design and production. Nick Charles, Head of Engineering at Quest Global, and Head of Advanced Manufacturing CoE Vijay Anand, will share expert insights on the importance of real-time synchronization and collaboration using these technologies. The session will include a case study demonstrating a successful implementation that led to significant reductions in cycle times and improved efficiency. By attending you will also gain actionable insights on how to begin integrating digital twin and digital thread solutions into their own operations, streamlining processes and fostering innovation.</p><h3 dir="ltr">Key insights include:</h3><ul><li dir="ltr"><p dir="ltr"><strong>Cutting the Design Cycle</strong>: Learn how digital twins help identify design issues early, verify interfaces, and conduct simulations of environmental behaviors and characteristics, drastically reducing design times and errors.</p></li><li dir="ltr"><p dir="ltr"><strong>Optimizing Manufacturing Methods</strong>: Discover how digital twins can improve the design of manufacturing tools and methods, enabling the use of Virtual and Smart Factories to boost production efficiency.</p></li><li dir="ltr"><p dir="ltr"><strong>Enhancing Predictive Maintenance:</strong> Gain insights into how digital twins enable real-time data analytics, helping to predict and prevent failures, extending equipment lifespan, and optimizing operational efficiency.</p></li></ul><h3>Speaker details</h3><table style="width: 100%;"><tbody><tr><td style="width: 50.6024%;"><p id="isPasted"><strong>Nick Charles</strong></p><p>Head of Engineering - UK Defense at Quest Global</p>Nick Charles is the Head of Engineering (UK Defence) at Quest Global and a seasoned engineering leader with extensive experience in the aerospace and defense sectors. Previously, he served as VP and Senior VP at Ultra Maritime, leading a team of over 800 engineers across five countries. Was responsible for challenging engineering projects and drove major improvements in engineering processes, team development, and risk management</td><td style="width: 49.3976%; vertical-align: top; text-align: left;"><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxMzI5NTIwODI1LW5pY2stY2hhcmxlcy1xdWVzdC1nbG9iYWwuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 331px;" class="fr-fic fr-dib"></p></td></tr><tr><td style="width: 50.6024%; vertical-align: top;"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI5NTk3MTYxMzY5LVZpamF5LUFuYW5kLVFHLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 315px;" class="fr-fic fr-dib"></td><td style="width: 49.3976%; vertical-align: top;"><p id="isPasted"><strong>Vijay Anand R (VJ)</strong></p><p>GM – Head of Advanced Manufacturing CoE at Quest Global</p>VJ is Head of Advanced Manufacturing CoE of Quest Global based out of Derby, UK.<br>He is a veteran of Manufacturing Engineering for over 30 Years, both with Traditional and Digital manufacturing.<br>He is heavily influenced by Toyota way of working and embraced the same in his roles at Quest Global while managing Global manufacturing team and solutions for major Aerospace &amp; Defense, Energy and Transportation customers till date.<br>He has been instrumental in setting up a Digital Manufacturing Lab in partnership with Siemens to Design, Develop and Simulate the manufacturing and assembly operations. He also represented Quest Global for a Major Aero Engine customer’s Digital Manufacturing Focus Group conferences held at various global locations.</td></tr><tr><td style="width: 50.6024%; vertical-align: top;"><p id="isPasted"><strong>Luke Logan</strong></p>Luke Logan is a seasoned business leader with a significant career in engineering and technology. With over three decades of senior executive experience, Luke has led global teams and managed major projects at Rolls-Royce plc, BAE Systems plc, and Weir Group plc—three of the world's leading engineering and technology companies. His broad expertise across sectors such as Civil Aerospace, Defence, Power, and Industrial Equipment enables him to share a wealth of insights and foster diversity of thought.<br>Now, as an independent advisor and consultant, Luke applies his extensive experience to support the growth and development of his clients' businesses. He is deeply committed to diversity &amp; inclusion, innovation, and aligning engineering professionalism with business success and sustainability. Luke is a Fellow of The Royal Academy of Engineering, the Institute of Mechanical Engineering, and the Royal Aeronautical Society.</td><td style="width: 49.3976%; vertical-align: top;"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTMyMDkwODQ3LUlNR18zNTM4LmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 346px;" class="fr-fic fr-dib"></td></tr></tbody></table><h3><br></h3>

Discover how digital twins are revolutionizing aerospace manufacturing by cutting design cycles, driving predictive maintenance, and improving manufacturing efficiency.

Unlocking the Potential of Digital Twins for Aerospace Manufacturing: New Webinar

<p dir="ltr" id="isPasted">Tight schedules and narrow profit margins often challenge innovators in the electronic product development process. Engineers determined to stay at the cutting edge need access to the latest tools and technologies to continue pushing the envelope.</p><p dir="ltr">The global virtual ATCx Electronics for Engineers 2024: Riding the Crest of Innovation event offered valuable insights into how simulation and AI are transforming electronic design across industries. Featured presentations from leading companies demonstrated successful implementations of data-driven design strategies in specialised tracks covering automotive, aerospace, and high-tech sectors.&nbsp;</p><p dir="ltr">In addition, the event featured<a href="https://altair.com/resource/eda-more-critical-more-valuable-more-exciting-than-ever" target="_blank" rel="noopener noreferrer"> a keynote with Joe Costello, former CEO at Metrics </a>and considered to be one of the founders of the modern EDA industry, where he reflected on the last 40 years of the industry and what he predicted for the future of electronics and semiconductor design.</p><p dir="ltr" id="isPasted">In the Altair Resource Library you can find recordings of all featured tracks from the event covering the automotive, aerospace, and high-tech sectors:</p><p dir="ltr"><a href="https://altair.com/resourcelibrary?keywords=2024&category=ATCx%20Electronics&lang=English" target="_blank" id="isPasted" class="button-main-action" rel="noopener noreferrer">View all presentations</a></p><h2 dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0ODU3NzI2MjAxLWV5SmlkV05yWlhRaU9pSjNaWFp2YkhabGNpMXdjbTlxWldOMExXbHRZV2RsY3lJc0ltdGxlU0k2SW1aeWIyRnNZUzh4TnpJME9EVTFNRGM1T1RZM0xURTNNalE0TlRVd056azVOamN1Y0c1bklpd2laV1JwZEhNaU9uc2ljbVZ6YVhwbElqcDdJbmRwWkhSb0lqbzVOVEFzSW1acGRDSTZJbU52ZG1WeUluMTlmUT09LndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></h2><h1 dir="ltr">Featured Presentations</h1><h3 dir="ltr">Panel - The Next Wave: Innovations and Obstacles in Electronics &amp; Semiconductors</h3><p dir="ltr">Sarmad Khemmoro, I SVP – Technical Strategy, Electronics Design and Simulation, Altair I</p><p dir="ltr">Simon Segars | Former CEO | ARM &amp; Joe Costello | Former CEO | Metrics</p><p dir="ltr">In this engaging Fireside Chat, Sarmad Khemmoro, SVP, &nbsp;will lead the discussion around the latest innovations and trends shaping the electronics and semiconductor technology landscape. This engaging and informative discussion will bring together industry pioneers Joe Costello and Simon Segars, who will share their experiences, insights, and forecasts for the future of electronics and semiconductor design.</p><p dir="ltr"><a href="https://altair.com/resource/the-next-wave-innovations-and-obstacles-in-electronics-and-semiconductors" target="_blank" rel="noopener noreferrer">Link to the presentation</a></p><h3 dir="ltr">EDA - More Critical, More Valuable, More Exciting than Ever</h3><p dir="ltr">Joe Costello I Former CEO | Metrics</p><p dir="ltr">Considered to be one of the founders of the modern EDA industry, Joe Costello will be the keynote speaker at this event where he will be reflecting on the last 40 years of the industry and what he predicts for the next 10 years.</p><p dir="ltr" id="isPasted"><a href="https://altair.com/resource/eda-more-critical-more-valuable-more-exciting-than-ever" target="_blank" rel="noopener noreferrer">Link to the presentation</a></p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0ODU3NTk2OTk2LUFsdGFpcl9MUF9BdXRvbW90aXZlX0hlcm9fZGVza3RvcC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><h1 dir="ltr">Track 1: Automotive / Transportation</h1><p dir="ltr">In this track you can engage and learn from global companies on how they are addressing their electronic system design challenges. Presenters from Jaguar Landrover, Tata Motors, Kion Group, Aptiv, AmpX, and Ashok Leyland, are on the agenda.</p><h3 dir="ltr">Accelerating Product Design and Testing for Automotive Power Electronics</h3><p dir="ltr">Dr. Zeyu Zhang | Co-Founder, Vice President Engineering | AmpX</p><p dir="ltr">The design for automotive powertrain components is a comprehensive and sometimes iterative process. There always exists a gap between simulation and testing results. In this presentation, we will share perspectives of how we utilize Altair PSIM to enhance the design and testing process based on an onboard charger example.</p><p dir="ltr" id="isPasted"><a href="https://altair.com/resource/accelerating-product-design-and-testing-for-automotive-power-electronics" target="_blank" rel="noopener noreferrer">Link to the presentation</a></p><h1 dir="ltr">Track 2: Aerospace / Defense</h1><h3 dir="ltr">Compact Converters Using GaN HEMTs for Isolated RF Power Applications</h3><p dir="ltr">Dr. Harish Krishnamoorthy, Associate Professor, University of Houston</p><p dir="ltr">Pulsed power applications require the delivery of high-energy pulses in a controlled and efficient manner. Power converters need to be specifically designed to meet the demanding requirements of pulsed power systems, providing precise voltage and current regulation, fast switching capabilities, and high power density. Power supplies for pulsed power applications contribute to the advancement of various fields, including aerospace, defense, medical, and subsurface characterization.</p><p dir="ltr" id="isPasted"><a href="https://altair.com/resource/compact-converters-using-gan-hemts-for-isolated-rf-power-applications" target="_blank" rel="noopener noreferrer">Link to the presentation</a></p><h3 dir="ltr">Shift Left – Streamline Component Derating and Reliability Analyses in the Design Flow of Mission Critical Electronics</h3><p dir="ltr">Dr. Amir Segal I BQR</p><p dir="ltr">Mission critical electronics must be reliable, safe and robust. Therefore, reliability analyses should be an integral part of the design flow. Despite its crucial nature, reliability analysis is frequently sidelined in the design process, often due to disconnects between reliability departments and designers, compounded by inefficient communication methods such as spreadsheets.</p><p dir="ltr" id="isPasted"><a href="https://altair.com/resource/shift-left-for-reliability-your-secret-weapon-for-robust-mission-critical-electronics" target="_blank" rel="noopener noreferrer">Link to the presentation</a></p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0ODU3ODE0NDg2LXNodXR0ZXJzdG9ja18xNzE3Nzc3Nzk1LmpwZWciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><h1 dir="ltr">Track 3: High Tech</h1><h3 dir="ltr">ECAD to 3D PCB Results in a Day with Altair SimSolid®</h3><p dir="ltr">Evan Christensen I Senior Technical Account Manager, Altair</p><p dir="ltr">In conventional 3D PCB simulations, meshing is involved, which can be quite time-consuming but is essential for accurate results. However, SimSolid has revolutionized this process by eliminating the need for meshing, thereby significantly reducing the pre-processing time. Its highly efficient iterative solving technique is capable of handling large models, allowing engineers to evaluate design iterations much faster in their design cycles. This session will showcase hands-on demonstrations of how to quickly and efficiently develop 3D PCB designs.&nbsp;</p><p dir="ltr" id="isPasted"><a href="https://altair.com/resource/ecad-to-3d-pcb-results-in-a-day-with-altair-simsolid" target="_blank" rel="noopener noreferrer">Link to the presentation</a></p><h3 dir="ltr">Explore more presentation from ATCx Electronics 2024&nbsp;</h3><p dir="ltr">In Altair's resource library to discover more presentations from this year's ATCx Electronics for Engineers event.</p><p dir="ltr"><a href="https://altair.com/resourcelibrary?keywords=2024&category=ATCx%20Electronics&lang=English" target="_blank" class="button-main-action" rel="noopener noreferrer">View all presentations</a></p>

Watch featured presentations from the global virtual event.

Elevate Your Engineering Expertise: ATCx Electronics for Engineers 2024

<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 id="isPasted">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><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIzMTE2NDg1NjU0LXJvY2hlc3RlciBtb2NrdXAzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" 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: 540px; height: 300px;" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-lf-yt-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><h2 dir="ltr" id="isPasted">Solving component obsolescence challenges</h2><p dir="ltr" id="isPasted">Dealing with component obsolescence is one of the most challenging obstacles an avionics designer may encounter. In the previous installments of this article series, we discussed the impact and causes of component obsolescence, as well as practical techniques and resources to help navigate the complexities of obsolete components. In this piece, we’re going to look at some real-world examples of companies that worked alongside Rochester Electronics to solve their component obsolescence challenges.</p><h3 dir="ltr">Military aviation</h3><p dir="ltr">Rochester Electronics faced a challenging situation when approached by a manufacturer of engine control modules for the United States Military regarding field failures in aircraft engine control modules<sup>[1]</sup>. These failures were traced back to counterfeit microprocessors, which a manufacturer had procured from a grey market source instead of purchasing authorized devices. This decision, initially made to reduce costs, led to a series of failures and malfunctions in aviation equipment.</p><p dir="ltr">As failures mounted, the gravity of the situation became clear. Military aircraft were at risk, and the lives of service members were at risk. Meanwhile, the manufacturer found itself facing costly recalls and substantial fines. The initial cost savings quickly evaporated in the face of these unforeseen expenses and the potential for even more severe consequences.</p><p dir="ltr">The original components' obsolescence compounded the problem. The original manufacturer no longer had the necessary test protocols for these outdated devices, making it challenging to prove the components were counterfeit definitively.&nbsp;</p><p dir="ltr">Rochester’s role in resolving this obsolescence challenge was multifaceted. As a 100% authorized and licensed partner, Rochester possessed the necessary test IP to prove the components were counterfeit conclusively. It then supplied the manufacturer with authorized, licensed devices that performed flawlessly in the field and met the stringent safety requirements of military aviation. Rochester Electronics’ components eliminated the need for time-consuming redesign or requalification processes, allowing for a swift resolution to the crisis.</p><p dir="ltr">Rochester Electronics takes pride in its 100% certified, authorized, and licensed manufacturing processes. All its components are guaranteed and sold under the original manufacturer's part number, giving customers confidence in their authenticity and reliability. Additionally, it offers ISO-9001, AS9120, and (QML) MIL-PRF-38535 certifications and QSLD qualification.</p><h3 dir="ltr">Avionic Flash Memory</h3><p dir="ltr">A major global aerospace manufacturer faced a dilemma when they learned that the NAND flash memory device for their avionics systems was being discontinued by the Original Component Manufacturer (OCM)<sup>[2]</sup>. The situation presented a potential crisis, as replacing the component proved far from straightforward.</p><p dir="ltr">The manufacturer needed to find a form, fit, and functional replacement that could utilize the available die while replicating the multi-die package required for their product. They were keen to avoid the substantial expenses associated with a last-time buy (LTB), the carrying costs of stocking the product, and, most importantly, a costly redesign of their systems.</p><p dir="ltr">Rochester Electronics proved uniquely positioned to address this challenge. With their extensive experience in component replication and strong relationships with OCMs, they were able to offer a comprehensive solution.</p><p dir="ltr">The company's in-house team, working with full OCM approval, successfully reverse-engineered the package. This meticulous process allowed Rochester to provide authorized components that were 100% form, fit, and functionally equivalent to the original. Importantly, this meant no software changes were required, saving the manufacturer from a time-consuming and expensive DO-254 recertification process.</p><p dir="ltr">Through this process, Rochester also ensured the customer had a continuous, authorized supply of these components for the next 7-10 years and beyond. Their long-term solution ultimately eliminated the need for the manufacturer to make a large last-time buy or incur ongoing inventory-carrying costs.</p><h3 dir="ltr">Military hybrid Modules</h3><p dir="ltr">Our final case study comes from a client of Rochester’s, an aerospace and defense technology company that needed to guarantee a continuous supply of custom electronic hybrid modules for long-life military applications<sup>[3]</sup>. These hybrid modules were considerably complex, consisting of multiple semiconductor components, passives, and hermetically sealed substrate packages.</p><p dir="ltr">Specifically, the company required a custom military hybrid module initially designed in the 1970s. Unsurprisingly, the original equipment manufacturer (OEM) no longer supported new builds, and the necessary active semiconductor components were unavailable on the open market. This situation threatened the continuity of specific military programs and posed a risk of costly redesigns, development, testing, and re-qualification.</p><p dir="ltr">Seeking a solution, the company approached Rochester Electronics for specialized assembly services. They needed a partner capable of providing high-frequency assembly and test support based onshore in the United States and with full ITAR compliance, and Rochester fit the bill.</p><p dir="ltr">Rochester’s extensive capabilities in supporting long-life military applications, coupled with their US-based manufacturing facilities and ITAR registration, made them uniquely qualified to tackle the problem. For example, their 60,000-square-foot Newburyport, Massachusetts, facilities were perfectly equipped to handle the hermetic assembly services required for this project.</p><p dir="ltr">The project progressed through detailed reviews and a prototype phase, where 100 units of prototype hardware successfully passed qualification and met all program requirements. These prototypes had to meet numerous technical specifications, including specialized substrate and chip attachments, wire bonding, hermetic sealing, and rigorous testing protocols.</p><p dir="ltr">The hybrid module assembly has since moved into full production, with over 3,000 parts delivered to date.&nbsp;</p><h1 dir="ltr">Solving Component Obsolescence&nbsp;</h1><p dir="ltr">Rochester Electronics has been helping customers understand, navigate, and solve their avionics component obsolescence challenges for decades. Like the companies demonstrated in these case studies, your team can rely on Rochester to help resolve any obstacles associated with obsolete components.</p><p dir="ltr">Learn more about solving their component obsolescence challenges in the latest whitepaper from Rochester.&nbsp;</p><p dir="ltr"><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/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: 540px; height: 300px;" 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">Read more in the series:</p><p dir="ltr" id="isPasted"><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><p dir="ltr">[1] <a href="https://rocelec.widen.net/s/vv6kzd5mql/military_aviation_case_study_safetyfirst" target="_blank">https://rocelec.widen.net/s/vv6kzd5mql/military_aviation_case_study_safetyfirst</a></p><p dir="ltr">[2] <a href="https://rocelec.widen.net/s/qjm2pdrqzv/aerospace-_case-study" target="_blank">https://rocelec.widen.net/s/qjm2pdrqzv/aerospace-_case-study</a></p><p dir="ltr">[3] <a href="https://rocelec.widen.net/s/bcwcdtgtmw/hybrid-module-assembly_case-study" target="_blank">https://rocelec.widen.net/s/bcwcdtgtmw/hybrid-module-assembly_case-study</a></p>

Futureproofing Aerospace Series. Article #6. These real-world examples show how to manage component obsolescence for avionics designs effectively.

Case Studies in Managing Avionics Component Obsolescence

<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 id="isPasted">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><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyNTkwOTg3MTU4LXJvY2hlc3RlciBtb2NrdXAzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" 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: 275px;" 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></iframe></span></p><h2 dir="ltr">Managing avionics obsolescence</h2><p dir="ltr" id="isPasted">The meteoric rate of technological advancement, coupled with the long lifecycle of avionics systems, poses a significant challenge: component obsolescence. If not managed proactively, avionics obsolescence can disrupt operations, increase costs, and compromise safety. To mitigate these risks, it is essential to implement strategies that anticipate obsolescence and address it before it impacts operations<sup>[1]</sup>.&nbsp;</p><p dir="ltr">Rochester Electronics has spent decades helping customers prevent and deal with obsolescence should it occur. In this piece, we’ll discuss how predictive tools, strategic partnerships, inventory management, and lifecycle planning are all important strategies for managing avionics obsolescence.&nbsp;</p><h1 dir="ltr">Predictive Tools for Anticipating Obsolescence</h1><p dir="ltr">Predicting component obsolescence is one major proactive method for managing electronic components' lifecycles<sup>[2]</sup>. This process involves forecasting when a component will become obsolete by heavily analyzing historical data, market trends, and lifecycle information provided by manufacturers.</p><p dir="ltr">In many cases, advanced algorithms and specialized software tools can be employed to assess these data points. These tools can offer detailed analysis by considering factors such as the rate of technological advancement, shifts in market demand, and manufacturers’ product roadmaps. By predicting obsolescence, companies can strategically plan for last-time buys, find alternative components, or redesign products, ensuring that supply chain disruptions are minimized.</p><p dir="ltr">Proactive obsolescence management is also essential for maintaining production schedules and reducing costs associated with sudden component unavailability. It allows for better inventory management, avoiding excess stock of soon-to-be obsolete components and reducing the need for expensive and time-consuming redesigns. &nbsp;</p><p dir="ltr">Furthermore, effective obsolescence prediction supports long-term strategic planning. By understanding the lifecycle of components, companies can better align their product development timelines and technology investments with market realities, ensuring sustained competitiveness and innovation. It also enables better supplier relationships, as companies can work collaboratively with component manufacturers to stay informed about potential obsolescence issues and jointly develop mitigation strategies.</p><h1 dir="ltr">Strategic Partnerships with Suppliers</h1><p dir="ltr">Forming strategic partnerships with suppliers is another effective strategy for managing avionics obsolescence.&nbsp;</p><p dir="ltr">Close collaboration with suppliers can ensure a steady supply of components and facilitate early warnings about potential obsolescence issues. Suppliers can provide companies with valuable insights into component lifecycles, availability, and potential substitutes, enabling companies to make informed decisions about their inventory and procurement strategies.</p><p dir="ltr">Strategic partnerships also foster mutual trust and cooperation, which can be beneficial in negotiating favorable terms for component purchases and securing long-term supply agreements. These partnerships can also lead to joint development efforts, where suppliers work with companies to develop custom components that meet specific requirements and have longer lifecycles.</p><h1 dir="ltr">Inventory Management</h1><p dir="ltr">Effective inventory management is another essential tool for mitigating the impact of avionics obsolescence.With an accurate and up-to-date inventory of components, companies can quickly identify which parts are at risk of becoming obsolete and take appropriate action. This may involve increasing stock levels of critical components, finding alternative parts, or initiating a redesign of affected systems.</p><p dir="ltr">To this end, advanced inventory management systems can track component usage and availability in real-time. Such systems can also integrate with predictive tools to provide a comprehensive view of obsolescence risks and enable proactive management.</p><p dir="ltr">In addition to tracking inventory, companies should also implement strategies for managing excess and obsolete stock. This may involve selling surplus components, returning unused parts to suppliers, or recycling materials. By effectively managing inventory, companies can reduce waste, lower costs, and ensure the continuous availability of critical components.</p><h1 dir="ltr">Lifecycle Planning</h1><p dir="ltr">Lifecycle planning involves anticipating and managing the entire lifecycle of avionics components, from design and development to production, deployment, and eventual retirement. By considering obsolescence at each stage of the lifecycle, companies can develop strategies to mitigate risks and ensure the longevity of their systems<sup>[3]</sup>.</p><p dir="ltr">During the design phase, engineers should consider the availability and longevity of components, selecting parts with long lifecycles and multiple sources of supply. Design for obsolescence, which involves creating systems that can be easily upgraded or modified, can also help mitigate the impact of obsolescence.</p><p dir="ltr">In the production phase, companies should establish robust processes for monitoring component availability and managing supplier relationships. This may involve implementing rigorous quality control measures, conducting regular supplier audits, and maintaining contingency plans for sourcing critical components.</p><p dir="ltr">During deployment, companies should continuously monitor the performance and availability of components, using predictive tools and inventory management systems to identify potential obsolescence issues. By staying informed about component lifecycles and market trends, companies can take proactive steps to secure necessary parts and avoid disruptions.</p><p dir="ltr">Finally, during the retirement phase, companies should have a plan for phasing out obsolete systems and transitioning to new technologies. This may involve conducting regular system performance reviews, identifying opportunities for upgrades, and working with suppliers to develop replacement components.</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIyNTkwNjI3MjMzLTE3MjI1OTA2MjcyMzMucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="351" class="fr-fic fr-dii"></p><h1 dir="ltr">Regulatory Compliance and Operational Efficiency</h1><p dir="ltr">Regulatory bodies, such as the Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA), have strict requirements for the maintenance and certification of avionics systems<sup>[4].</sup> An inability to comply with these regulations, due to obsolete components or otherwise, can result in costly fines, operational disruptions, and reputational damage.</p><p dir="ltr">By implementing proactive strategies for managing obsolescence, companies can demonstrate compliance with regulatory requirements and reduce the risk of non-compliance. This can involve maintaining detailed records of component lifecycles, conducting regular audits of systems and processes, and ensuring that all modifications and upgrades are properly documented and certified.</p><p dir="ltr">Operational efficiency is also enhanced by proactive obsolescence management. By anticipating and addressing obsolescence issues before they impact operations, companies can avoid costly downtime, minimize maintenance costs, and bolster the overall reliability of their systems. This can lead to increased operational availability and a competitive advantage in the market.</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">Proactive management of avionics obsolescence is essential for allowing the continuous availability and reliability of avionics components. By leveraging predictive tools, forming strategic partnerships with suppliers, implementing effective inventory management practices, and planning for the entire lifecycle of components, companies can anticipate and mitigate obsolescence risks before they impact operations.</p><p dir="ltr">Rochester Electronics works with customers to help them act ahead of time and develop a comprehensive approach to obsolescence management. Together with their customers, they aim to safeguard operations, reduce costs, and maintain their competitive edge in the market. In the next article in this series, we’ll take a look at specific examples of avionics customers who have benefited from working with Rochester Electronics.&nbsp;</p><p dir="ltr">Learn more about aviation obsolescence in our latest whitepaper.&nbsp;</p><h3 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: 275px;" 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>Read more in the series:</h3><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><p dir="ltr">[1] <a href="https://www.rocelec.com/news/the-proactive-approach-to-obsolescence" target="_blank">https://www.rocelec.com/news/the-proactive-approach-to-obsolescence</a></p><p dir="ltr">[2] <a href="https://www.rocelec.com/news/predicting-component-obsolescence" target="_blank">https://www.rocelec.com/news/predicting-component-obsolescence</a></p><p dir="ltr">[3] <a href="https://www.rocelec.com/news/component-management-begin-before" target="_blank">https://www.rocelec.com/news/component-management-begin-before</a></p><p dir="ltr">[4] <a href="https://www.faa.gov/about/initiatives/cp" target="_blank">https://www.faa.gov/about/initiatives/cp</a></p>

Futureproofing Aerospace Series. Article #5. The best time to deal with component obsolescence is before it even happens.

Proactive Strategies for Managing Avionics Obsolescence

<p id="isPasted">The aerospace and defence industry is known for producing complex and advanced products—jet engines, aircraft, rockets, satellites, drones, and more—that move fast in a highly regulated environment. It is no wonder that these factors of speed, complexity, and policy compliance play key roles in the manufacturing process. This design tip explores how to improve aerospace development cycles through:</p><ul type="disc"><li>accelerating production with digital manufacturing</li><li>reducing components, which helps in lightweighting part design, cuts items in an overall assembly, and reduces costs</li><li>using a range of manufacturing methods and materials, which can accelerate development and add value to your designs</li><li>streamlining quality and compliance assurances</li></ul><p>1. Use Digital Manufacturing to Accelerate Product Development</p><p>At Protolabs, we understand the importance of speed. Working extensively with companies in the <a href="https://www.protolabs.com/en-gb/materials/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" title="Aerospace" target="_blank">aerospace and defence industry,</a> we have accelerated the development over the years of a range of metal and plastic aerospace parts and products that include:&nbsp;</p><ul type="disc"><li>Heat exchangers</li><li>Manifolds</li><li>Turbo pumps</li><li>Liquid and gas flow components</li><li>Fuel nozzles</li><li>Conformal cooling channels</li></ul><p>&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIxNzQ4NjM3Njg2LTE3MjE3NDg2Mzc2ODYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"></p><p>Metal aerospace parts have been produced by a range digital manufacturing methods, including GE’s additively manufactured fuel nozzle, left, for CFM International’s LEAP aircraft engine, right.</p><p>One of the drivers in our success is through experience and rigorous development of digital manufacturing tools. We have found the right blend of working with autonomous digital tools and hands-on application engineers to meet aerospace demands.</p><p>When starting the digital manufacturing process with many manufacturers, it can be easy to upload a CAD file into multiple online quoting tools.</p><p>Unfortunately, some manufacturers' online quoting tools don’t take into account all of the back-end requirements, or offer all of a manufacturer’s processes. This is where we choose to be upfront so that each step required for the part or project is reflected in the initial quote.</p><p>When using online digital tools, quoting software can greatly accelerate development and production cycles.</p><p>However, to get the most out of these tools, make sure you are working with software (and a manufacturer) that includes the following:</p><ul type="disc"><li>Takes into account all requirements and steps of the build or project</li><li>Offers all available processes and materials&nbsp;</li><li>Offers trained and experienced staff with years of manufacturing experience&nbsp;</li></ul><p>A major challenge in the aerospace and defence industry is on-time delivery and quality. Industry sources say around 80% of orders generally show up on time. Yet, when those orders do show up on time, about 25% of parts do not meet the required quality. A common complaint from aerospace companies is when vendors promise a lead time with a cheaper price but could not deliver within the timeline quoted. Delays have led to missed deadlines and greater costs to fix than if they would have just started with the higher-priced vendor.</p><p>Our <a href="https://www.protolabs.com/en-gb/industries/aerospace-defence/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" title="Sample Quote" target="_blank">online, interactive quoting system</a> turns your CAD model into a quote with immediate design analysis and feedback. Your design can be reworked to determine the ideal balance of processes, materials, time, and cost. This greatly increases efficiency as it isn’t necessary to talk with someone every time a part is needed. But when you need a knowledgeable person on your side, we have a team of applications engineers ready to back up our automated tools. All contacts, customer or not, get free access to our responsive team that understands how to design for our processes, reduce cost, and answer a myriad of other technical questions.</p><p>2. Reduce Components to Benefit Product Design</p><p>You may want to reduce overall components in a part or product design for several reasons.</p><p>First, lightweighting is crucial in aerospace. Companies know just how many ounces of fuel it takes to fly a gramme of weight in flight, for example, so slight reductions drive major gains. The choice of materials, and sometimes the method of manufacturing, also factor into this lightweighting equation. But trimming part count helps, too.</p><p>Second, cutting costs is important. Plastics and metals can be expensive, and so can assembly time. Accordingly, if designs can lessen the number of components or parts, this can reduce materials and assembly time.</p><p><img border="0" width="570" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIxNzQ4NjAwNzgxLTE3MjE3NDg2MDA3ODEucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></p><p>Reducing components and combining part assemblies can improve aerospace product design in several ways: trimming a part’s weight, cutting costs, reducing inventory, and streamlining supply chains.</p><p>With these lightweighting and cost considerations in mind, which materials work best for aerospace components? Titanium is often a go-to choice, available through machining and 3D printing services. This lightweight and strong material offers excellent corrosion and temperature resistance. Aluminium, and its high strength-to-weight ratio makes it a good candidate for housing and brackets that must support high loading. Aluminium also is available for both machined and 3D-printed parts. Inconel, a 3D-printed metal, is a nickel chromium superalloy ideal for rocket engine components and other applications that require high-temperature resistance. Stainless steel also is a frequent materials choice. For example, SS 17-4 PH is used in the aerospace industry due to its high strength, good corrosion resistance, and good mechanical properties at temperatures up to 315 degrees C. Like titanium, it can be machined or 3D printed. Liquid silicone rubber is also widely used in the industry. This elastic fluorosilicone material is specifically geared toward fuel and oil resistance while optical silicone rubber is a good PC/PMMA alternative. Common applications in aerospace include soft-touch surfaces, gaskets, seals, and O-rings.</p><p>Finally, beyond lightweighting and cost cutting issues, the aerospace industry faces unique benefits and challenges with high risks and rewards. Companies are concerned with development cycles, prototyping, hot-fire testing, and production. So, while component reduction can help reduce part weight and assembly time, the real savings are in the reduction of the headaches and overhead associated with the supply chain and paper trail for each part. In aerospace, each component that goes into the final product has a tremendous amount of validation behind it such as material traceability, shock and vibe tests, rigorous inspections, and much more. In such a regulated industry, reducing parts can provide great value by reducing inventory, having fewer documents to track, and streamlining your supply chain.</p><p>3. Deploy a Range of Manufacturing Methods, Materials</p><p>If you have an internal machine shop but have to deal with a lot of different types of manufacturing in a small space, you might have taken projects to outside vendors for development work. It is important to find the right vendor with the capacity to meet your high demands for quality and speed. You may know but it bears repeating that there are no universal processes or materials. You need all the tools in your arsenal to find the best solutions to stay on the cutting edge. Therefore, work with companies that are able to offer a range of manufacturing processes and materials. We offer CNC machining, sheet metal fabrication, injection moulding, and five different industrial-grade 3D printing (additive manufacturing) methods in-house, more via our network. Additionally, you can choose from hundreds of commercial-grade plastics, metals, and elastomers that are suitable for both prototyping and production. See our <a href="https://www.protolabs.com/en-gb/automated-design-analysis/#samplequote ?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">Materials Comparison Guide</a> for a complete list.</p><p>Subtractive Processes and Materials:</p><p>CNC machining methods, specifically three- and five-axis milling, are frequently used in manufacturing today. &nbsp;For the aerospace industry, common materials are aluminium, hard metals such as 304, 316, and 17-4PH stainless steel, and titanium.</p><p>What isn’t common are the size and geometric dimensioning and tolerancing (GD&amp;T) capabilities of many shops. While it is common for the customer to state what tolerances are needed, look for companies that state what size and GD&amp;T they can deliver. &nbsp;&nbsp;</p><p>Most aerospace customers have complex parts that can be more advanced than even our automated machining facilities can handle.</p><p>For detailed information on &nbsp; tolerances, minimum and maximum part dimensions, and other design guidelines, visit our <a href="https://www.protolabs.com/en-gb/materials/comparison-guide/%20?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">basic design guidelines</a> for CNC milling.</p><p>Additive Manufacturing—Processes and Materials:</p><p>A considerable amount of aerospace and defence parts are metal. Accordingly, when it comes to metal 3D printing or additive manufacturing, most common materials are Inconel 718, the aluminium alloy AlSi10Mg, stainless steel (304 &amp; 17-4), titanium, and cobalt chrome (CoCr). Again, the difference here will be the material and additive manufacturing processes available.</p><p>&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIxNzQ4NzAxMzEwLTE3MjE3NDg3MDEzMTAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib"></p><p>DMLS can additively manufacture large, production-grade metal parts (as shown). This large-format metal 3D printing, from our GE Additive Concept Laser X-Line machine, is an example of how our company is technology agnostic, using machines, equipment, and processes sourced from a variety of companies.</p><p>We use multiple additive processes: stereolithography, direct metal laser sintering (DMLS), selective laser sintering, Multi Jet Fusion, &nbsp;and PolyJet. DMLS has proven to be a desirable process in the aerospace industry because it offers:</p><ul><li>large range of materials</li><li>increased functionality</li><li>ability to accommodate complexity and organic designs</li></ul><p>Beyond the manufacturing methods referenced (subtractive and additive), we also offer a number of secondary or finishing options, if your design calls for these applications:</p><ul><li>Post-process machining - for 3D-printed metal parts</li><li>Heat treatment</li><li>Anodising</li><li>Basic assembly</li><li>Chromate plating</li><li>Cleaning</li><li>Part marking</li><li>Plus more via our network</li></ul><p>If you need several vendors for different processes or secondary processes, remember the benefits mentioned earlier about using one supplier with multiple processes. We offer many processes and materials while operating as a local vendor to reduce time and costs.</p><p>4. Rely on Quality and Compliance Assurance</p><p>Finally, aerospace product designers and developers need to carefully navigate government and safety policy and compliance issues. Working in such a highly regulated industry, it is important to find vendors familiar with aerospace requirements. Traceability, documentation, testing, and certified parts that are compliant in an ISO 9001 and AS9100D environment can decrease much of the work needed to be done, tested, or verified in house.</p><p>Governing bodies are continuously working on standards for additive manufacturing, so knowing exactly what is needed may be difficult to find for non-traditional processes. However, standards or certifications for finished parts apply no matter how it was manufactured. You will want to make sure vendors have certified materials, powder analysis, material traceability, and more depending on your needs. &nbsp;&nbsp;</p><p>We have already invested heavily in digital manufacturing methods to provide you with automated tools, documentation, testing, and traceability, all supported by our applications engineers, delivering you a streamlined and efficient digital thread. We offer the following quality documentations and report options in an ISO 9001, and (through our network) AS9100D compliant environment:</p><ul><li>Material certifications</li><li>Certificate of conformance (CoC)</li><li>First article inspections (FAI)</li><li>Various other inspection requests such as CMM, X-Ray or CT scanning</li></ul><p>Visit these pages for more information on product design and development for the aerospace and defense industry.</p><p><a href="https://www.protolabs.com/en-gb/services/cnc-machining/cnc-milling/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">GUIDE: Combining Part Assemblies with Additive Manufacturing</a></p><p><a href="https://www.protolabs.com/en-gb/resources/guides-and-trend-reports/combining-part-assemblies-with-additive-manufacturing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">Aluminium Alloys: Go-to Materials for Automotive, Aerospace, and More</a></p><p><a href="https://www.protolabs.com/en-gb/resources/blog/aluminium-alloys-go-to-materials-for-automotive-aerospace-and-more/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">Shortening the Development Cycle in the Aerospace Sector</a></p><p><a href="https://www.protolabs.com/en-gb/resources/blog/shortening-the-development-cycle-in-the-aerospace-sector/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">Lockheed Martin's Small Drone with a Big Spirit</a></p><p><a href="https://www.protolabs.com/en-gb/resources/case-studies/lockheed-martin/%20?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-aerospace-parts-0724&utm_content=wevolver-0724" target="_blank">Airbus makes high-voltage progress in electric aviation</a></p><p>Ultimately, we will work with you to find the best solution and consider all steps of your project. If you would like more information, contact our applications engineers at +44 (0) 1952 683047, email us at customerservice@protolabs.co.uk, or start your design today by <a href="https://identity.protolabs.com/signup?lang=en-GB&returnUrl=%2fconnect%2fauthorize%2fcallback%3fclient_id%3dcommerce-spa-global-client%26code_challenge%3dKbYXzo0VMu1xKxihpf7snbZoIxyF7HEk6o_CVytqS3c%26code_challenge_method%3dS256%26getaquote%3dtrue%26lang%3den-GB%26redirect_uri%3dhttps%253A%252F%252Fbuildit.protolabs.com%252Fhandshake%26response_mode%3dquery%26response_type%3dcode%26scope%3dopenid%2520profile%2520email%2520phone%2520address%2520offline_access%2520global-api-access-scope%26state%3d37fc8343cf234cda8ac5d6a95863affc" target="_blank">uploading your 3D CAD model</a> to receive an interactive quote within hours.</p>

4 ways to improve product development in aerospace and defense using speed, component reduction, multiple manufacturing methods, and quality assurance.

A Guide to Manufacturing Aerospace Parts

<p id="isPasted">In the world of high reliability connectors, those destined for spaceflight face the toughest conditions. Missions can last years and travel huge distances with no chance for repairs. Connectors need to provide secure communications, even in the harsh environments found outside the atmosphere.</p><p>The exploration of space is very much in the news. &nbsp;One of the largest programs in recent space history is the Artemis program. This program will see humanity return to the Moon, and its launch vehicle is the Space Launch System. &nbsp;Completing its first successful mission in December 2022, the SLS forms the largest component of the program. However, the latest steps in our return to the Moon are not the only exciting initiatives in space.</p><p>The James Webb Space Telescope (JWST) was launched late in 2021. It is still sending us detailed images of galaxies born in the earliest days of the universe. &nbsp; The information that JWST has gathered is providing new insights into how stars and galaxies are formed. Its advanced capabilities will pave the way for some truly remarkable discoveries in the future. &nbsp;In addition to scientific missions, the last few years have also seen the beginning of an entirely new industry. Some of the richest people on Earth have offered tempting visions of commercial space tourism.&nbsp;</p><p>These high-profile events, while they capture the imagination of the public, represent just a small part of the picture. &nbsp;The exploration and exploitation of space is an everyday activity. There were more than 220 space launches in 2023 alone <sup>[1]</sup>, carrying science missions and satellites into orbit and beyond. &nbsp;</p><h2><strong>The Toughest Environment</strong></h2><p>Even though spaceflight has become more common, the conditions in which these systems must perform are unlike any other. Space represents possibly the single most demanding environment known to engineering. &nbsp;Any equipment used in spaceflight is exposed to a whole range of extremes, from high and low temperatures and harsh radiation to the rigours of launch <sup>[2]</sup> and the vacuum of space. &nbsp;</p><p>The lack of atmosphere is especially unforgiving. On Earth, our atmosphere serves as a protective blanket that provides pressure, thermal insulation, and safety from harmful radiation. In space, this protection is stripped away, exposing equipment to potential damage.</p><p>Without the atmosphere to protect it, an object in space receives the full force of the sun’s radiation. &nbsp;When equipment is bombarded by direct sunlight, its temperature can quickly become dangerously high. In contrast, the parts of a spacecraft that remain in shadow are very cold. &nbsp;These extremes of temperature need to be considered when selecting the materials to be used aboard space vehicles. &nbsp;There are other sources of radiation, including galactic cosmic rays which are highly ionizing. &nbsp;These can harm delicate instruments or sophisticated electronic circuits.</p><p><span class="fr-img-caption fr-fic fr-dii" style="width: 780px;"><span class="fr-img-wrap"><img width="602" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIxMzg2NzIwNjA2LTE3MjEzODY3MjA2MDYuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="A large white object with a metal frameDescription automatically generated with medium confidence" class="fr-fic fr-dii"><span class="fr-inner">Connectors have been providing reliable service in space for decades<br>&nbsp;Image credit: Author</span></span></span></p><h2><strong>The Dangers of Outgassing</strong></h2><p>The lack of atmospheric pressure also causes materials to behave in unique ways. &nbsp;Outgassing <sup>[3]</sup> is a process in which a gas that has become trapped inside another material is released. &nbsp;This is a common problem when plastic is exposed to a vacuum during spaceflight, but it is not limited to plastics alone. &nbsp;Some metals are also prone to sublimation in vacuum conditions, including zinc and cadmium, both of which are commonly used in conventional equipment design. &nbsp;&nbsp;</p><p>In both cases, the gas that is released can cause damage. &nbsp; It may condense onto cold surfaces such as the optics and sensors of scientific equipment. &nbsp;This can degrade or even negate their effectiveness and put the entire mission at risk. Components also need to be mechanically robust as launching satellites, probes and spacecraft into orbit exposes them to acceleration and vibration that can cause damage that might be undiscovered for months or years. Plastic components need to be manufactured of materials that exhibit high stability, even in vacuum conditions. &nbsp;</p><p>To provide solutions for these demanding conditions, connectors designed for spaceflight connectors are amongst the most advanced in the industry. &nbsp;Manufactured to stringent standards and tested to prove their performance even in the vacuum of space, they are the very definition of high reliability connectors.</p><h2><strong>Maximizing Endurance</strong></h2><p>If the spaceflight environment is not tough enough, there is one additional aspect that contributes to the challenges of designing for spaceflight, and that is endurance. &nbsp;Missions to space, whether they are intended for commercial purposes or scientific, can last for years. &nbsp;If a piece of equipment fails, it is impossible to gain access to fix the problem. &nbsp; In these circumstances, designers and engineers depend on the reliability of each of the components that make up the equipment, no matter how small.</p><p>Endurance also plays a key role in power planning. A long-range probe operates on a very strict power budget, and a component that introduces unwanted electrical resistance will risk jeopardizing the mission. &nbsp;The electrical contacts used in space-rated connectors will be made from the finest materials and manufactured to the closest tolerances. &nbsp; Contacts will be plated with gold to a thickness rarely seen in even the most demanding applications back on Earth. &nbsp; Gold plating ensures that the contact resistance is kept as low as possible to reduce power loss.</p><p>Contacts with a low electrical resistance are important for other reasons. &nbsp;Despite the sophistication of the instruments mounted to space probes, the measurements being taken can be tiny. &nbsp;When scientists are looking for minute fluctuations within magnetic fields or are trying to isolate a radiation signature from the noise of interplanetary space, unwanted electrical resistance can prevent a critical signal from being collected.&nbsp;</p><p>This is also the reason that manufacturers go to the trouble of reducing the magnetic signature of the components themselves to prevent interference with precision scientific experiments. Connectors designed for spaceflight applications use materials that provide the best possible performance. &nbsp;In just one example, the key feature of the D-subminiature connector is the trapezoidal shell that provides protection to the contacts and ensures correct mating. &nbsp;Traditional D-subs use shells made of steel, but versions destined for spaceflight use brass to minimize their magnetic signature. &nbsp;</p><p>The shell also provides protection against electromagnetic interference (EMI) <sup>[4]</sup>. &nbsp;In the vacuum of space, unprotected by a blanket of atmosphere, equipment is exposed to solar radiation which can interfere with scientific observations or even damage sensitive instruments. &nbsp;The shells of many spaceflight connectors are gold-plated in the same way as the electrical contacts to provide the best possible protection against EMI.</p><p><span class="fr-img-caption fr-fic fr-dii" style="width: 780px;"><span class="fr-img-wrap"><img width="601" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIxMzg2NzIwNjE3LTE3MjEzODY3MjA2MTcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Several different types of computer connectorsDescription automatically generated" class="fr-fic fr-dii"><span class="fr-inner">Spaceflight Connectors<br>&nbsp;Image credit: Glenair</span></span></span></p><p><br></p><h2><strong>Conclusion</strong></h2><p>Connectors play an often-overlooked role in spaceflight applications. Space vehicles are typically manufactured from sub-assemblies which are brought together before launch. Connectors provide the vital interface between each system, during both the extensive testing regime before launch and the demanding conditions found in space. Spaceflight connectors are designed to some of the highest standards in the interconnection industry and, as a result, represent some of the most capable products available today.</p><h3>References</h3><ol start="1" type="1"><li><a href="https://www.spaceworks.aero/recap-of-all-global-launches-for-2023/" target="_blank">https://www.spaceworks.aero/recap-of-all-global-launches-for-2023/</a>&nbsp;</li><li><a href="https://blogs.nasa.gov/Rocketology/2016/02/25/think-youre-stressed-try-being-a-rocket/" target="_blank">https://blogs.nasa.gov/Rocketology/2016/02/25/think-youre-stressed-try-being-a-rocket/</a>&nbsp;</li><li><a href="https://blog.samtec.com/post/what-is-outgassing-and-how-is-it-tested/" target="_blank">https://blog.samtec.com/post/what-is-outgassing-and-how-is-it-tested/</a>&nbsp;</li><li><a href="https://www.techtarget.com/searchmobilecomputing/definition/electromagnetic-interference" target="_blank">https://www.techtarget.com/searchmobilecomputing/definition/electromagnetic-interference</a>&nbsp;</li></ol><p><br></p>

Delivering the performance demanded by today’s space missions requires the ultimate in high-reliability connectors.

High Reliability Connectors in Space

<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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From Documents to Models: Improving System Architecture and Design Validation in Aerospace With Model-Based Systems Engineering (MBSE)