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MILITARY, AEROSPACE & DEFENCE


INDUSTRY FOCUS


CONNECTING DESIGN AND PRACTICAL SKILLS THROUGH


AEROSPACE ELECTRONICS TRAINING


As aerospace systems become more dependent on advanced electronics, the skills required to design, assemble, inspect and rework


them are changing, as John Vickers, Advanced Rework Technology master trainer, explains


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cross the aerospace sector, more functionality is being incorporated into compact, densely populated assemblies on


which wider system performance can depend. Reliability starts with design, but design intent


must be carried successfully into production. Component layout, material selection and thermal behaviour influence how an assembly is soldered, inspected and, if necessary, repaired. Electronics training should therefore connect design decisions with the practical processes used to turn them into dependable hardware. In aerospace electronics, a design decision


that restricts access, a poorly formed solder joint or a defect missed during inspection, can put high-value hardware at risk. Training helps designers understand the production implications of their choices while giving technicians and inspectors the practical skills to apply requirements consistently.


DESIGN IN PRACTICE A Design for eXcellence approach considers manufacturing, assembly, inspection, testing and possible rework alongside circuit functionality. It includes Design for Manufacture, Design for Assembly and Design for Test, helping engineers anticipate later production stages. This requires designers to understand how decisions made during PCB development affect the people and processes that follow. Component spacing and orientation, pad


design, thermal mass and the position of connectors or shielding can all influence production. A component placed close to a taller device may restrict soldering and inspection access. If it later needs to be replaced, the same layout may make it difficult to apply heat without affecting adjacent components. Designers do not need to become production


technicians, but training should give them an understanding of assembly, inspection and the practical consequences of layout choices. This supports better discussions before a design is released. The exchange must work in both directions.


Recurring difficulties involving access, heat distribution or inspection may identify improvements for future designs. Training helps technicians, inspectors and designers recognise


www.designsolutionsmag.co.uk and communicate the significance of these issues.


SKILLS IN PRODUCTION Miniaturisation has reduced the space available for soldering and rework. Fine-pitch devices, densely populated printed circuit boards and mixed assembly technologies require technicians to control small quantities of solder, work under magnification and apply heat within restricted areas. Insufficient heat may prevent the required


connection from forming. Excessive or prolonged heating can damage component terminations, pads, laminate materials or nearby joints. Physical force during component removal can lift lands or damage plated-through holes. Practical training allows technicians to repeat representative tasks, understand how materials respond and correct their technique before working on production hardware. Training must extend beyond soldering.


Component handling, electrostatic discharge precautions, cleanliness and correct tool use can affect whether an assembly meets its design requirements. Technicians may also need skills in cable and wire harness integration, inspection and controlled rework. The Global Electronics Association’s IPC


standards provide recognised requirements and acceptance criteria. IPC J-STD-001 covers the production of soldered assemblies, while IPC-A- 610 provides criteria for assessing completed work. IPC/WHMA-A-620 addresses cable and wire harness assemblies, and IPC-7711/7721 covers rework, modification and repair. Aerospace assemblies may be required to meet


Class 3 criteria, which apply to high-performance electronic products where continued operation is critical. The standards, classification and additional requirements are determined by the contract, customer documentation and manufacturer’s quality system. Knowing a standard is different from applying


it. Standards-based practical training allows technicians and inspectors to examine acceptable and unacceptable conditions, interpret the criteria consistently and demonstrate that they can complete relevant tasks correctly. Inspection is part of the connection between design and production. Magnification may be


needed to identify insufficient solder, bridging, disturbed joints or damage to conductors and component terminations. Connections beneath ball grid array packages cannot be assessed fully through external visual inspection and may require X-ray examination. Automated optical inspection and X-ray


equipment provide useful information, but personnel must understand their limitations. Finding a defect is also different from determining its cause. Investigation may consider layout, materials, equipment settings, handling and the wider process, informing production controls and future designs.


MAINTAINING KNOWLEDGE Aerospace manufacturers must retain these skills as experienced personnel leave. Practical knowledge may not be captured fully in design rules, assembly instructions or inspection criteria. Structured training transfers knowledge and assesses competence before employees work independently. Continued development is equally important.


Refresher training and certification renewal help maintain capability as standards, components and inspection methods change. Electronics training should reflect individual responsibilities, while helping designers, technicians, inspectors and rework specialists understand how their decisions affect the wider assembly. Automation will continue to change how


aerospace electronics are inspected and processed, but it does not remove the need for people who can interpret results, investigate defects and make judgement calls on complex hardware. By linking design knowledge with standards-based practical skills, electronics training helps ensure that aerospace designs can be manufactured, inspected and supported to the standard the application demands.


Advanced Rework Technology www.rework.co.uk


SEPTEMBER 2026 DESIGN SOLUTIONS 25


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