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Ruggedized Solutions with Trusted and Proven Reliability
Evaluating and comparing rugged COTS boards and systems can be confusing. Although military ruggedization standards simplify the process, techniques and methodologies to ensure ruggedness and reliability can differ from one vendor to another. Curtiss-Wright goes beyond standard industry processes to deliver ruggedized solutions with trusted and proven reliability that cannot be matched in the industry. We use the insight gained through advanced reliability analysis and testing to optimize designs and improve reliability. Testing for failures begins in the earliest development stages and continues throughout the manufacturing process.
To ensure Curtiss-Wright products do not fail in the field, products undergo rigorous testing to the point of failure in the lab. Review the Curtiss-Wright standards for ruggedization in the table below.
New Levels of Reliability
With Curtiss-Wright's highly scientific approach to advanced reliability testing, analysis, and failure mitigation, reliability reaches the highest possible levels in every aspect of solution design. Curtiss-Wright uses finite element analysis (FEA) tools to model mechanical designs and regularly test hardware, components, and connectors on representative boards to ensure product integrity. For example, all circuit card assemblies (CCAs) are subjected to shock and vibration testing to understand, measure, and mitigate fretting wear and corrosion on connectors.
Additionally, extensive time and effort go into rigorous thermal testing and analysis to ensure solutions perform reliably for years in extreme environments. Thermal designs are modeled and thoroughly tested to increase power dissipation while remaining within device limits. Some of Curtiss-Wright's innovations in this area include using:
- TherMax thermal frame designs increase heat flow from components to the external thermal interface
- Heat shunts from hot components to an unused chassis interface above the wedgelock
- Heat shunts from high-power PMC modules directly to the thermal interfaces
- The first effective solution development using heat pipes to cool high-power processor devices
World Class Manufacturing
To ensure that no printed wiring board (PWB) weaknesses go undetected, Curtiss-Wright takes its reliability testing, fault identification, and mitigation techniques to microscopic levels. This comprehensive approach has been practiced for years.
Curtiss-Wright has tested and proven a superior solution to mitigate against pad cratering that has been deployed for a decade. Pad cratering occurs when mechanical stress, such as temperature, vibration, or PWB bending, creates tiny cracks that detach the pad from the PWB, leaving a "crater" on the board. This insidious failure can plague high-reliability electronics and is often difficult to detect.
Curtiss-Wright leads industry efforts in applying conformal coatings, cleaning techniques, and lead-free soldering techniques that are proven to mitigate against tin whiskers effectively. These needle-like, crystalline structures are 10 to 100 times thinner than a human hair yet conduct electricity, potentially causing short circuits on CCAs.
Results of Curtiss-Wright's extensive failure testing and analysis have led to several operational improvements, including:
- Reliability risk assessment (RRA) and mitigation on all new solutions, leveraging data from our extensive reliability knowledge database
- Reliability prediction tools
- PWB design and fabrication and in-house manufacturing to IPC Class 3 enhanced with additional rules
- Extensive qualification testing with full functional testing
- VITA 47 Reliability Demonstration Testing (RDT)
- In-house manufacturing to IPC Class 3
- Environmental Stress Screening (ESS) for all ruggedized solutions
- A micro sectioning lab for failure analysis
- Solution reliability tracking
Together, these initiatives serve as a strong foundation to advance failure detection and analysis capabilities, further increasing the long-term reliability of Curtiss-Wright products in the field. That reliability is one of the key reasons Curtiss-Wright has been a trusted provider of rugged and reliable solutions that has been proven in the field for a decade.

Beyond Ruggedization: Ensuring Long-Term Reliability
Curtiss-Wright Standards for Ruggedization
Environmental Condition | Air-Cooled Level 0 | Air-Cooled Level 50 | Air-Cooled Level 100 | Conduction-Cooled Level 0 | Conduction-Cooled Level 100 | Conduction-Cooled Level 200 | Conduction-Cooled Level 300 | Air Flow Through (Note 6) |
---|---|---|---|---|---|---|---|---|
Operating Temperature | 0 to 50°C (Note 4) | -20 to 65°C (Note 4) | -40 to 71°C (Note 4) | 0 to 50°C (Note 7) | -40 to 71°C (Note 7) | -40 to 85°C (Note 7) | -40 to 85°C (Note 7) | 0 to 55°C (Notes 4, 8) |
Non-Operating Temperature (Storage) | -40 to 85°C | -40 to 85°C | -55 to 125°C | -40 to 85°C | -55 to 125°C | -55 to 125°C | -55 to 125°C | -55 to 125°C |
Non-Operating Humidity (Storage) | 0-95% non-condensing | 0-100% non-condensing | 0-100% non-condensing | 0-95% non-condensing | 0-100% non-condensing | 0-100% non-condensing | 0-100% non-condensing | 0-100% non-condensing |
Vibration Sine (Note 1) | 2g Peak 5-2000Hz | 2g Peak 5-2000Hz | 10g Peak 5-2000Hz | 2g Peak 5-2000Hz | 10g Peak 5-2000Hz | 10g Peak 5-2000Hz | 10g Peak 5-2000Hz | 10g Peak 5-2000Hz |
Vibration Random (Note 2) | 0.04 @ 5Hz 0.04 @ 100Hz 0.01 @ 2000Hz | 0.04 @ 5Hz 0.04 @ 100Hz 0.01 @ 2000Hz | 0.002 @ 5Hz 0.04 @ 15Hz 0.04 @ 2000Hz | 0.04 @ 5Hz 0.04 @ 100Hz 0.01 @ 2000Hz | 0.005 @ 5Hz 0.1 @ 15Hz 0.1 @ 2000Hz | 0.005 @ 5Hz 0.1 @ 15Hz 0.1 @ 2000Hz | 0.005 @ 5Hz 0.1 @ 15Hz 0.1 @ 2000Hz | 0.005 @ 5Hz 0.1 @ 15Hz 0.1 @ 2000Hz |
Shock (Note 3) | 20g Peak | 20g Peak | 30g Peak | 20g Peak | 40g Peak | 40g Peak | 40g Peak | 40g Peak |
Altitude (Notes 9) | -1,500 to 60,000 ft | -1,500 to 60,000 ft | -1,500 to 60,000 ft | -1,500 to 60,000 ft | -1,500 to 60,000 ft | -1,500 to 60,000 ft | -1,500 to 60,000 ft | -1,500 to 60,000 ft |
Conformal Coat | No | Consult Factory | Yes | No | Yes | Yes | Yes | Yes |
2 Level Maintenance Covers | - | - | - | - | No | No | Yes | Yes |
Engineered for Ruggedization and Reliability





Thermal Management in Rugged Computer Systems
This white paper looks at the different cooling techniques available including conduction, convection, Air-Flow-Through (AFT), Liquid-Flow-Through (LFT), and Fluid-Flow-Through (FFT).

Thermal Management in Rugged Computer Systems
This white paper looks at the different cooling techniques available including conduction, convection, Air-Flow-Through (AFT), Liquid-Flow-Through (LFT), and Fluid-Flow-Through (FFT).
Take Embedded Systems to New Extremes Deliver Cutting-Edge Reliability With COTS Products
The VITA 47 standard defines a set of rigorous environmental, design, and construction, safety, and quality requirements for plug-in COTS hardware that is intended for use in mobile defense and aerospace applications.

Take Embedded Systems to New Extremes Deliver Cutting-Edge Reliability With COTS Products
The VITA 47 standard defines a set of rigorous environmental, design, and construction, safety, and quality requirements for plug-in COTS hardware that is intended for use in mobile defense and aerospace applications.
Durability of COTS Modules in Tactical Fighter Environments
With the move to more open systems architectures, it's time to re-evaluate COTS modules to see how rugged they can be in tactical fighter environments.

Durability of COTS Modules in Tactical Fighter Environments
With the move to more open systems architectures, it's time to re-evaluate COTS modules to see how rugged they can be in tactical fighter environments.
COTS Boards Brochure
COTS products and open-architecture solutions for mission computing, signal processing, graphics, communication fabrics, system and sensing I/O, and data storage.

COTS Boards Brochure
COTS products and open-architecture solutions for mission computing, signal processing, graphics, communication fabrics, system and sensing I/O, and data storage.
System Solutions Brochure
Whether looking for a modular, SFF LRU or a scalable VPX systems designed to meet program requirements, Curtiss-Wright computing systems are built rugged to perform optimally in the harshest environments.

System Solutions Brochure
Whether looking for a modular, SFF LRU or a scalable VPX systems designed to meet program requirements, Curtiss-Wright computing systems are built rugged to perform optimally in the harshest environments.
Aerospace Instrumentation Brochure
Largest data acquisition provider in the world. See our full range of cutting-edge Aerospace Instrumentation products.

Aerospace Instrumentation Brochure
Largest data acquisition provider in the world. See our full range of cutting-edge Aerospace Instrumentation products.
Addressing the Challenges of Lead-free Technology in Mil-Aero Electronics White Paper
The use of lead-free COTS components for advanced technology military applications impacts the industry considerably.

Addressing the Challenges of Lead-free Technology in Mil-Aero Electronics White Paper
The use of lead-free COTS components for advanced technology military applications impacts the industry considerably.
Defense Solutions Product Guide
Explore Curtiss-Wright's mission-critical solutions based on the latest technologies and open standards. These innovative solutions are trusted and proven for aerospace and defense applications.

Defense Solutions Product Guide
Explore Curtiss-Wright's mission-critical solutions based on the latest technologies and open standards. These innovative solutions are trusted and proven for aerospace and defense applications.