Aerospace PCB Manufacturing

Aerospace PCBs must meet far more stringent requirements than standard circuit boards. They need to withstand extreme temperatures, vibrations, and pressures found in flight and space environments. Materials used are often specialised for thermal stability and resistance to humidity, corrosion, and radiation. 

Aerospace PCBs are designed for high reliability, with rigorous testing and quality control, including compliance with standards such as AS9100 and IPC Class 3. Traceability throughout manufacturing is also critical for safety and certification. These boards often incorporate advanced features like multilayer construction, controlled impedance, and rigid-flex designs to handle complex signals and compact spaces. The result is a PCB built not just to function but to perform flawlessly throughout long missions in unforgiving conditions.

Key certifications for aerospace PCB manufacturers include AS9100, ISO 9001, and IPC-A-610 Class 3. AS9100 is the aerospace industry’s standard for quality management, focusing on risk management, traceability, and continuous improvement. ISO 9001 covers broader quality management systems but is also essential for ensuring consistent manufacturing processes. 

IPC-A-610 Class 3 certification specifies the highest quality standards for electronic assemblies, crucial for mission-critical aerospace equipment. These certifications demonstrate a manufacturer’s commitment to quality, reliability, and regulatory compliance. Additionally, compliance with environmental regulations such as RoHS may be necessary.

Altimex ensures reliability through strict quality control, from design to delivery. We use high-grade materials suited for aerospace environments and follow detailed manufacturing processes compliant with ISO9001 and IPC standards. Every board undergoes thorough inspection methods, including automated optical inspection (AOI), X-ray analysis, and electrical testing.

Our traceability systems track every step of production, enabling full accountability and compliance with aerospace regulations. We also offer design-for-manufacturability (DFM) support to minimise risks early in the process. Environmental and stress testing simulate extreme conditions to confirm board durability.

Aerospace applications utilise a range of PCB types depending on the function and environment. Multilayer PCBs are common due to their ability to handle complex circuits and high-density connections within compact spaces. Rigid-flex PCBs combine flexibility and strength, ideal for tight or moving parts. 

Single-sided and double-sided PCBs may be used in less complex systems. Flexible PCBs offer vibration resistance and adaptability in confined areas.

Manufacturing aerospace PCBs can take longer than standard boards due to the complexity, testing, and certification involved. Typical lead times vary from two to eight weeks, depending on factors such as board complexity, material availability, and production volume. 

Rapid prototyping options may shorten initial turnaround times, but full production usually requires thorough quality checks and documentation for compliance. Custom testing and inspection add time but are vital for reliability. Working with experienced manufacturers like Altimex ensures realistic lead time, estimates, and transparency throughout the process, helping aerospace companies plan projects effectively without compromising quality.

Yes, Altimex offers prototyping services tailored for aerospace PCBs. Early-stage prototypes allow engineers to test designs, verify functionality, and identify potential issues before committing to full production. Our prototyping process includes quick turnaround times and collaboration on design for manufacturability. 

We use the same high-quality materials and processes as production boards to ensure accuracy. This approach helps reduce risks, saves costs, and accelerates time-to-market. Clients benefit from our expertise in aerospace standards and testing to refine their PCBs and ensure the final product meets all performance and regulatory requirements.

Aerospace PCBs undergo extensive testing to guarantee performance and reliability. Common methods include automated optical inspection (AOI) to detect manufacturing defects, X-ray inspection for internal layer integrity, and electrical testing to verify circuit continuity and isolation. Environmental stress tests simulate extreme temperature ranges, humidity, vibration, and shock to confirm durability under flight conditions. 

Conformal coating inspections ensure protective layers are properly applied. Altimex also performs functional testing where circuits are evaluated in real operational scenarios. This multi-level testing process meets or exceeds industry standards, ensuring PCBs are ready for mission-critical aerospace use.

Aerospace PCBs often use specialised materials designed for extreme conditions. Common substrates include polyimide, known for excellent thermal resistance and flexibility, and Rogers laminates, valued for their stable dielectric properties at high frequencies. These materials help PCBs maintain signal integrity and mechanical strength under thermal cycling and vibration. 

Copper foils may be thicker to improve current-carrying capacity. Protective coatings, such as conformal coatings, guard against moisture, dust, and corrosion. Selecting the right materials is critical to ensure PCBs meet aerospace reliability, safety, and performance standards.