Avionics

In the recent past, state-of-the-art digital avionics solutions have become essential to the development cycles of the aerospace and defense industry. OEMs and Tier 1 suppliers are striving to provide lighter, more compact, and energy-efficient avionic systems where software becomes an integral part in realizing avionic functions. As the life expectation of a typical avionic system is more than 30 years, companies face the need to extend the product life of the component, upgrade the technology, and consequently redesign the component due to obsolescence in 20–30 years.

System and integrated engineering capabilities play a vital role in the development of several areas such as glass cockpits, integrated modular avionics systems, and common architecture solutions across multiple aircraft/avionic programs. With our motto of ‘Designing Tomorrow Together,’ at Cyient, we collaborate with avionics OEMs worldwide to develop innovative next-generation avionics systems, by delivering complete system engineering solutions from requirement definition to the certification audit.

Our integrated process assimilates system, software, hardware, packaging design, and test engineering competencies to deliver avionic systems that are ARP4754A development assurance level (DAL) A to E compliant. We provide civil and military avionics engineering solutions for electrical systems, communication systems, navigation systems, and cockpit avionic systems&#8212such as PFD/MFD displays, flight control systems, control and diagnostics, cabin and cargo management systems, and air management systems. We design and engineer these systems to meet the certification objectives of RTCA DO-254 for sophisticated electronic hardware, RTCA DO-178C for software and environmental compatibility, complying with RTCA DO-160G for commercial aviation, and MIL-STD-810F for defense systems.

We offer our aerospace design and development capabilities to support obsolescence analysis of existing products. We also take up obsolescence-mandated redesign of in-service LRUs/LRMs, testing, environmental qualification, and manufacturing of avionic LRUs/LRMs in a low-cost country, with our AS9100C and Nadcap-approved manufacturing facilities.

Cyient’s avionics portfolio is bolstered by the acquisition of CERTON which extends our capabilities around safety-critical systems, embedded software, and electronic hardware certification. Core competencies encompass process-oriented product development lifecycles where testable requirements are developed to support fully automated independent verification and validation. Our safety-critical certification engineering services focus on rapid automation of requirements capture, simulation, validation, and verification testing wherever possible to reduce project timeline and cost.

We combine our aerospace experience, integrated avionics product development processes, and systems engineering expertise to develop or upgrade LRUs/LRMs at a lower cost and with a shorter lead time. Using flexible business models such as time & material, firm fixed price, risk and revenue sharing, and co-development business models; we partner with our clients to successfully design, develop, and deliver next-generation avionics engineering products.

Our avionics capabilities include:

Solutions Expertise in
System development lifecycle activities Complete product lifecycle including planning, requirements, design, integration, problem report management, validation, verification, and certification support (according to SAE ARP 4754A).
Electronics hardware design, verification and validation lifecycle Planning, requirements, conceptual design, detailed design and analysis, implementation, verification and qualification of complex electronic hardware (CEH), and Circuit Card Assembly (CCA) as per RTCA DO-254.
Embedded software design, verification and validation lifecycle Complete product lifecycle including planning, requirements, design, implementation, integration, and verification as per RTCA DO- 178C.
System and CCA test engineering and ATE development Circuit board and Line Replaceable Unit (LRU) test plans, environmental qualifications, platform based ATE design and development, customized test system development.
Aerospace process-based integrated project management Integrated project plan, project specific process, monitoring and control of projects, integrated product development process (systems, hardware, software, mechanical, manufacturing and after sales support).
Mechanical design and engineering System, sub-assembly, and component design; modelling and analysis (structural and thermal), reverse engineering, simulations, and CFD.
Safety and reliability engineering System safety assessment (SSA), Single Event Effect (SEE) analysis, Common Mode Analysis (CMA), Fault Tree Analysis (FTA), and reliability prediction to MIL-STDs/ SAE ARP4761.
Technical publications Detailed engineering drawings, component maintenance manuals, and user manuals.
Design analysis Stress analysis, worst case analysis, signal integrity, design FMEA, thermal analysis, design for “ilities” (DFM/DFA/DFT/EMI/EMC/…), and obsolescence analysis.
Circuit board assembly and production PCB assembly—SMT and PTH, ROHS, REACH, lead/lead-free, IPC-610E, Class II/III, J-STD-001E, Nadcap approved PCB process, AOI, x-ray inspection, conformal coating, IRIS/ISO9001/AS9100/ISO13485 approved assembly, and ICT/FPT testing.
Prototyping PCB prototyping, rapid prototyping, LRU build, test jigs, fixtures build, and tooling.
Cable harness design and manufacturing Design and route electrical wiring, harnessing, cabling using schematics, Bill of Material (BOM), advanced testing.
LRU chassis machining LRU mechanical enclosure, precision machining on aluminum, Inconel, titanium and magnesium, RF antenna.
Automated testing, certification and conformance Proprietary tools and bench testing environment to support fully automated testing, qualification and pass/fail determination—for software, hardware, and tools.
HASS/HALT testing Environmental Stress Screening (ESS), component level screening, determine screening levels, operating and destruct margins.
Consulting and training Cyient provides consulting and training for DO-178C and DO-254 processes.
Model Based Design Model based design utilizing CertSAFE.
Tool qualification DO-330 tool qualification capabilities
Testing environment generation Real-time fully automated testing environment generation to support the use of automated test case execution and automated determination of pass/fail on electronic mission critical systems.

Our avionics engineering capabilities—through our partner ecosystem:

Solutions Expertise in
Part manufacturing Enclosure manufacturing using aluminum alloy 6061, part tooling, and finishing process.
Packaging manufacturing Electronic packaging for enclosures, hermetically sealed casing semi gaskets, and card cages.
Sourcing of electronic parts Supply chain management, procurement specialists, End-of-Life (EOL), complete BOM sourcing, RoHS compliance, and global sourcing.
Environmental qualification testing MIL-STD-461C/E, MIL-STD-810G, RTCA DO-160, IEC 61000 pre-qualification tests.

Click here for more information about our avionics portfolio.

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