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Multilayer PCB Reverse Engineering

While there are any number of companies who claim to be able to reverse engineer and manufacture dual sided PCB’s, the skills necessary to create form-fit-function replacements of multilayer pcb’s in the world of military equipment and systems, reduce this list substantially. Competencies required for this analysis go well beyond point to point connectivity and encompass the full spectrum of electrical component and load analysis all in service of a form-fit-function replacement at the boundary. Keep in mind that depending on the goals of the project, the new pcb might internally look quite different than the original pcb design when one considers goals of cost reduction, obsolescence, and component availability.

What Capabilities are needed for CCA Reverse-Engineering?

When an original TDP is incomplete, incorrect, or not at all available, then a team like PHT Aerospace is needed to insure that a fully procurable, cost effective spare can be created and manufactured. To perform this work, the following capabilities are critical:

1.       Ability to comprehend the complete electrical specification and tolerances at the margins of the systems under discussion.

2.       Ability to reverse engineer in three dimensions, the mechanical footprint of the board and surface or attached components so as to fit perfectly into a preexisting backplane enclosure

3.       Advanced understanding of power consumption and power distribution across a multilayer pcb.

4.       Ability to produce hardened FPGA’s to replace older discrete TTL components for better cost and reliability.

5.       Ability to understand environmental requirements at both component and system level and the ability to qualify the design over a range that may be as much as -40C to 125C, the full mil spec temperature range.

6.       Complete understanding of both military and commercial avionics qualification processes and documentation.

7.       Ability to build custom test sets for qual of reengineered system that presents original electrical stimulus for all functional use cases, at the boundaries.

8.       Ability to manufacture a fully qualified and functional pcb. A willingness to potentially do this in small production quantities.

9.       Ability to produce Gerber Files and/or a complete TDP for resulting design.

10.   Ability to support critical subsystems in the field when necessary.

Unique PCB Reverse Engineering Capabilities

In just one example, PHT was able to successfully reverse engineer the pcb for multiple CCA’s for an advanced radar system for the F16 fighter jet.  In this application, existing scematic documentation was incorrect and original gerber files for the multilayer pcb were not available. In our analysis, we found small but catastrophic missing, erroneous, or out-of-date technical information which we had to verify and correct in order to be able to develop and manufacture a FFF CCA. As part of this work, PHT Aerospace developed a methodology, which mitigates many of the known performance risks and resulted in a CCA that worked in the rest of the system, even though documentation for the rest of that system was not even available.

For further information on our team and our capabilities in the military aerospace arena and beyond, please contact us today.

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PHT Aerospace LLC Corporation Awards WSI Digital Marketing and Website Re-engineering Contract

WSI has announced that it has recently partnered with the PHT Aerospace of Pompton lakes, New Jersey to redesign their website, increase their search visibility and implement a digital brand marketing program. The new website can be viewed at .

PHT Aerospace LLC is AS 9100D certified aerospace engineering and manufacturing company capable of designing new systems or reverse engineering parts to original specification. They provide help to develop specifications, reverse-engineer and re-design obsolete items, build and test prototypes and qualify systems through rigorous qualification testing. PHT has engineered, built, qualified, and managed production of subsystems for the US Navy, the US Air Force and many other subcontractors and manufacturers.

WSI Marketing Program For PHT Aerospace

WSI was engaged to do the web design and implementation, as well as provide all the copywriting and SEO operations for the new business initiative. WSI reviewed and did extensive background research on the competitive environment for reverse engineering companies, especially those with the AS9100D certification and designed a custom solution that would both lend credibility to the offline sales activities and improve brand visibility.

As a result of detailed competitive analysis, WSI created unique, SEO optimized page content catering to the unique and diverse product offering of the company. These custom pages and graphics developed by WSI include content for:

The marketing program that WSI has implemented for PHT Aerospace LLC includes organic Search Engine Optimization, content marketing and social media advertising. WSI’s SEO Program will also produce quality blog, graphic, social media and video content to syndicate on external web properties including WordPressWeeblyand Blogspot in addition to several other WSI proprietary content distribution platforms.

Call WSI for a Digital Branding Overview

For those looking to see what a truly intelligent and comprehensive marketing solution looks like, please give WSI a call today.

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Common Types of Aircraft Navigation Lighting

While military and commercial aircraft share some common conventions with respect to types, color and usage of external lights, differences exist in the goals and capabilities of similar systems. An obvious example might be the use of external lighting on stealth aircraft. It doesn’t help the cause if the enemy can see your wingtip lighting while you are miles from your approach. But on a commercial aircraft, not being able to see your wingtip lighting during a night approach could be tantamount to disaster.

Still, the common problems of visibility must be solved in non-combat situations and It turns out that something as seemingly simple as a light bulb, has many complexities when placed in the harsh environment of a jet during approach to a crowded city area runway. As designers of lighting systems on aircraft like the F16 and B1 bomber, PHT Aerospace understands the requirements of Aircraft Lighting Systems in both operational and production environments.

Wing-Tip Lighting – A.K.A. Navigation Lights

Aircraft navigation lights are required to be lighted on aircraft operated on the surface and in flight from sunset to sunrise. In addition, aircraft equipped with an anti-collision light system are required to operate that light system during all types of operations (day and night). However, during any adverse meteorological conditions, the pilot-in-command may determine that the anti-collision lights should be turned off when their light output would constitute a hazard to safety.

Anti-Collision Lighting

An aircraft anti-collision light system can use one or more rotating beacons and/or strobe lights. These are typically colored either red or white and have stronger intensities as compared to other aircraft. Many aircraft have both a rotating beacon and a strobe light system. Supplementary strobe lights should be turned off on the ground when they adversely affect ground personnel or other pilots, and in flight when there are reflections from clouds.

Wing lights

Many airliners feature lights along the root of the wing leading edge that can be used to illuminate the wing and engine pylons in flight. These lights may be used to make the plane more visible during takeoff and landing or to inspect the wings for damage in flight. Pilots can also use the wing lights to inspect the wings and slats for any ice that might build up when flying through clouds.

Landing lights

F16 On Takeoff

Bright white landing lights are usually fitted to most planes for enhanced visibility during landing. These lights can also be used to illuminate the runway at poorly lit airports. They are often required for night landings but also commonly used during the day as well to make the plane more noticeable. While the usage of these lights is common, their location can vary from plane to plane. Landing lights may be located in the wing root, in the outboard wing, or somewhere along the forward fuselage. Some aircraft are equipped with multiple sets of landing lights in more than one of these locations. The 737, for example, has inboard landing lights located in the wing root as well as outboard landing lights in the outboard flap fairings.

PHT Aerospace’s Team are Aircraft Lighting Experts

PHT Aerospace has the unique understanding of how to create form-fit-function replacement systems in the military and commercial aviation world. PHT has reverse engineered lighting systems for complex aircraft like the B1 bomber and the F16 and manages all production for these systems.

PHT can design and assume production of your aircraft lighting system be it commercial or military. We specialize in small quantity production.

Please call us today.

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AS91000 Certification

In 2018, PHT Aerospace achieved the AS9100 Revision D certification for quality management. As a premier provider of reverse engineering services for the military, the effort to qualify for this demonstrates our quality commitment to the marketplace, and the aerospace sector.

AS9100 Revision D is a quality management system standard for the aerospace industry. It is based on ISO 9001:2015, and provides additional requirements specific to the aerospace industry. Initially released by the Society of Automotive Engineers, SAE International in 1999, it has been revised since then from AS9000 to AS 9100. AS9100D is the latest release.

AS9100 is the result of the combined effort a various aerospace organizations that had each their own quality management standards or specifications. The harmonization of their requirements while using as a base ISO 9001, with its careful process related approach, drove the release of AS9100 and ended a period where it was extremely difficult to comply with the various requirements of these organizations.

PHT achieved AS9100D compliance by implementing additional requirements, which go above and beyond the quality requirements of ISO 9001 in order to ensure product safety and efficacy.

Just like other standards such as ISO 9001 and ISO 14001, certification assessments are done by registrars worldwide.

For more information visit our website at 

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Welcome to PHT Aerospace

Thanks for visiting our new digital home, 

PHT Aerospace provides general Military and Aerospace contract manufacturing. Typically our projects are under the DOD but often come to us through prime military contractors or other subcontractors. We also accept commercial avionics work in our  area’s of expertise.

These area’s include but are not limited to:

  • Power Supply Design – Either build to print or reverse engineered to preserve an existing system
  • Motors & Actuators – Either build to print or reverse engineered. Our systems control flight surfaces and other elements of active fighter jets.
  • Radar Systems – Either build to print or reverse engineered. We have extensive experience with FFF replacement of multilayer pcb’s when no TDP is available.
  • Aircraft lighting – a Special competency in aircraft navigation lights. We designed the lighting and power for the B1 wingtip lights among others.
  • Reverse Engineering for Obsolete parts and subsystems – including both electrical and mechanical FFF replacement.
  • Build To print – Production capabilities for those who want a fully qualified run from an experienced, DOD preferred vendor. Small production runs are not a problem for us

In 2017, PHT successfully achieved AS9100D certification as a demonstration of our long standing commitment to quality, and the aerospace sector in particular.

For more information, please contact us or visit our website at the link above.

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