Advanced Smart Factory Solutions for Commercial Aircraft Power Control Boards

Power control boards play a pivotal role in the electronics architecture of commercial aircraft. These PCBA products are used in critical systems such as cabin lighting control, in-flight entertainment, auxiliary power management, avionics interface modules, and environmental control systems. Given the mission-critical nature of these applications, the reliability, stability, and environmental protection of every power control PCB is of utmost importance.

Aircraft Power Control Boards

Aircraft Power Control Boards

At I.C.T, we understand the aviation industry's rigorous quality requirements. That’s why we offer a comprehensive SMT and conformal coating production line specifically tailored for manufacturing commercial aircraft power control boards.

SMT line Configuration for Commercial Aircraft Power Control Boards

• Solder Paste Handling

• PM-500 Solder Paste Mixer

• I.C.T-4034 Fully Automatic Stencil Printer

• Component Mounting

• PCB Loader + SC-500 SMT Conveyor

• Hanwha SM481PLUS + SM482PLUS High-Speed Chip Mounters

• STF100S Auto Tray Feeder

• PCB Transport

• TCR-L Turning Conveyors

• HC-2000 Connecting Conveyors

• Reflow Soldering

• L10 Reflow Oven (Nitrogen-enabled for zero-oxidation soldering)

• Inspection & Offloading

• UL-L Unloader

• V8 Offline AOI

• Custom Feeder & Nozzle Configurations

• Multiple CN series nozzles and 8–32mm feeders, tray, and vibration feeders

• Staffing Recommendation

• 1 Engineer

• 2 Operators

• 1 Quality Inspector

• Total: 4 personnel

Productivity Overview

• PCB size: 220 × 210 mm (6-panel array)

• Top Side

• 84 components/panel × 6 = 504 components/board

• Cycle time: 27s/board → 120 boards/hour = 720 PCBA/hour

• Bottom Side

• 80 components/panel × 6 = 480 components/board

• Cycle time: 35s/board → 102 boards/hour = 612 PCBA/hour

• Note: Productivity can be improved with offline programming and dual-machine optimisation

Power & Air Consumption

• Total rated power: 76.7 kW

• Operating energy consumption: approx. 24.6 kWh

• Air consumption: 5–10 m³/hour

This line configuration ensures IPC-A-610 Class 3 quality, necessary for aerospace reliability. Critical components like power ICs undergo selective or manual soldering, followed by nitrogen reflow processes to safeguard sensitive parts.

Conformal Coating line Configuration for Commercial Aircraft Power Control Boards

• PCB Handling

• I.C.T SC-500 Conveyor – Stable and consistent board transition

• I.C.T UV-1000 Coating Inspection Conveyor x2 – For pre- and post-coating visual checks

• Coating Application

• I.C.T T550 Selective Coating Machine – High-precision coating for defined areas

• Curing

• I.C.T IR Curing Oven – Uniform heating for consistent coating finish

• Staffing Recommendation

• 1 Operator

• 1 Quality Inspector

• Total: 2 personnel

  
  

Productivity Overview

• PCB size: 220 × 210 mm (6-panel array)

• Cycle time: approx. 30s/board → 120 boards/hour = 720 PCBA/hour

• Note: For fast-drying adhesives, ensure flow control to avoid defects like stringing or surface ripples. Dilution may be recommended to optimise viscosity and spray pattern.

Power & Air Consumption

• Total rated power: 18.5 kW

• Operating energy consumption: approx. 9.5 kWh

• Air consumption: 3–5 m³/hour

Application Focus: USB Power Control Boards in Commercial Aircraft

In today`s modern aviation industry, USB power control boards have become a vital element within commercial aircraft cabins. With passengers increasingly expecting seamless charging options during flight, these boards serve as the backbone for in-seat and wall-mounted charging post solutions, supporting USB and Type-C outputs while meeting stringent safety and performance requirements.

Unlike consumer-grade charging interfaces, these aircraft-specific power control boards must operate flawlessly under harsh environmental conditions — including rapid altitude changes, intense vibration, and electromagnetic interference. Designed to output stable 5V DC with overcurrent and short-circuit protection, they often feature intelligent power management, fault diagnostics, and load monitoring systems.

There are three main integration types in commercial aircraft:

• Seat-Integrated USB Boards – Embedded into the passenger seat, often connected to in-flight entertainment or PSU (Passenger Service Unit).

• Wall-Mounted Charging Posts – Installed in common areas such as galleys or near lavatories to allow communal charging.

• Multifunction Power Control Boards – Combine lighting, USB charging, and crew call functions for broader cabin control.

Each system must adhere to rigorous aerospace standards such as DO-160, ensuring operation in extreme conditions. They also use advanced interconnect technologies like MIL-DTL-38999 or ATP rectangular connectors with gold-plated beryllium copper contacts to ensure long-term durability and minimal electrical resistance — vital in aerospace environments.

Ready to Enhance Your Aircraft Charging Solutions?

Whether you`re designing the next-generation aircraft charging post PCBAs or upgrading your in-flight entertainment power infrastructure, I.C.T is ready to deliver a tailored solution.

Contact us for a free technical consultation or to schedule a line demo with our aerospace PCBA experts.