01
Rugged stackup
Filled and capped vias, no via-in-pad surprises, plated-through-hole reliability targets, conformal-coat or potting clearance baked into the floorplan.
Built to fly. Built to survive.
Aerospace and defense PCBs cost real money to re-spin and real lives to get wrong. We design to MIL-PRF-31032/55110, DO-254 airborne-hardware practice and IPC Class 3/3A — with ruggedization specified up front, not bolted on.
Class 3 / 3AIPC reliability
DO-254airborne-hardware aware
MIL-STD-810environmental margin
ASTM E595low-outgassing options
The deliverables.
02
DO-254 design data
Schematic, layout and verification artifacts structured to support DO-254 DAL-A through DAL-C objectives, with traceability your DER expects.
03
EMI / EMC for MIL-STD-461
RE102, CE102 and CS101 layout discipline: return-current control, shield-can footprints, filtered connectors integrated into the stackup, not added late.
04
Space-grade options
Low-outgassing prepregs (ASTM E595 < 1% TML, < 0.1% CVCM), de-rated voltages and tin-whisker-aware finishes for space and high-rel programs.
Built for this sector.
Standards we design to
- AS9100-aware design process
- DO-254 (airborne electronic hardware)
- MIL-PRF-31032 / MIL-PRF-55110
- MIL-STD-810 / MIL-STD-461 / MIL-STD-1275
- IPC Class 3 / 3A (IPC-6012 / A-600 Class 3)
Mission systems
- Avionics + flight controllers
- EW, SIGINT, radar front-ends
- Power distribution + solid-state SSPCs
- Sensor and IMU front-ends
- Comms (Link-16, SDR)
Rugged + space practice
- Filled / capped / plated-shut vias
- Conformal coat / parylene / potting
- De-rated voltages and thermal margin
- Low-outgassing material selection
- Tin-whisker mitigation
An SDR receiver re-spun for MIL-STD-810 vibration.
The brief
An anonymized SDR module passed at the bench but cracked solder joints during MIL-STD-810 random vibration. The board needed a re-spin, not another test.
What we did
- Re-oriented heavy connectors to the stiff edge and added staking pads to the largest SMD inductor.
- Switched the BGA pads to NSMD with rounded-corner copper escapes and added redundant traces on the safety-critical control net.
- Filled and capped the via-in-pads; bench-correlated the thermal map in TRM before committing to a re-fab.
Outcome
Cleared MIL-STD-810 vibration, MIL-STD-461 RE102 with 3 dB margin, and the customer’s de-rating audit — on the same article.
Common questions.
Are you ITAR registered?
We run controlled-data handling for ITAR projects on request. We aren’t a manufacturer — we’re a US-based design house with the data discipline ITAR work requires, and we’ll sign your TAA or equivalent agreement.
Do you support DO-254 DAL-A?
We support DAL-A through DAL-C layouts: independence, planned verification, traceable design data and review artifacts. Tool qualification and certification credit are your DER’s call — we deliver the data they need.
Can you do space-grade builds?
We pick low-outgassing materials (ASTM E595), de-rated voltages, tin-whisker-aware finishes and Class 3/3A practice. We aren’t flight-heritage on our own — we partner with a certified fab and add a heritage trail.
Make the qualification, not the re-spin.
DO-254 data, MIL-PRF stackup, Class 3 reliability. Fixed-fee band in 60 seconds.