Ensure your avionics systems can operate in harsh environments
Ensure your avionics systems can operate in harsh environments
RTCA DO-160 is a critical environmental and EMC testing standard for airborne equipment, developed by the RTCA (Radio Technical Commission for Aeronautics). It outlines a series of rigorous tests to ensure avionics systems can withstand the environmental conditions they’ll face in flight such as temperature extremes, vibration, shock, humidity, lightning strikes, and more.
DO-160 compliance matters because it ensures avionics equipment can operate reliably in harsh environments. Meeting this standard is essential for CAA, FAA and EASA certification, reduces risk of in-flight failures, and confirms equipment safety, durability, and performance across real-world aviation conditions.
RTCA DO-160 compliance is not just a regulatory checkbox. It's a critical step in ensuring the safety, reliability, and marketability of your airborne equipment. DO-160 compliance is important, if your business wants:
DO-160 is a foundational standard recognised by aviation authorities worldwide, including the CAA, FAA, EASA, and Transport Canada. Demonstrating compliance is often a mandatory requirement for aircraft certification and airworthiness approvals.
Avionics systems are exposed to extreme conditions such as temperature fluctuations, pressure changes, vibration, electrical disturbances, and more. RTCA DO-160 testing ensures your equipment can withstand real-world flight environments without failure, reducing the risk of in-service issues.
Non-compliant equipment can lead to system failures, costly recalls, or even safety incidents. By validating your product through DO-160 testing, you reduce the risk of operational failures and demonstrate due diligence in product development.
Early and thorough testing helps identify design weaknesses before production, avoiding delays during certification. This means faster development cycles and quicker entry into global markets.
Aircraft manufacturers and system integrators expect suppliers to meet DO-160 standards. Compliance builds trust and credibility, making your product more attractive to OEMs and Tier 1 suppliers.
In a highly regulated and competitive industry, having DO-160-tested products can set you apart. It signals engineering excellence, regulatory readiness, and a commitment to quality and safety.
Contact our team to learn more about how RTCA DO-160 testing can help your business.
We offer comprehensive environmental testing services in the UK across multiple DO-160 sections, including some of the following tests:
Simulates high-altitude and extreme temperature conditions.
Example: Avionics installed in the tail section of a commercial jet must operate reliably at -55°C and 50,000 ft, where air pressure is low and cooling is minimal.
Tests for rapid thermal cycling that can cause material fatigue or condensation.
Example: A flight data recorder may be exposed to quick transitions from hot tarmac to freezing altitudes during take-off, risking internal condensation.
Assesses resistance to prolonged exposure to high moisture levels.
Example: Cabin control units in tropical climates may face 95% humidity for extended periods, leading to corrosion.
Simulates mechanical shocks from rough landings or crash impacts.
Example: After a crash, emergency beacons must remain functional to transmit location data to rescue teams and cabin equipment and furniture must not detach.
Tests for continuous vibration from engines, air turbulence, or rotor blades.
Example: A navigation system mounted near a helicopter engine must endure constant vibration without signal drift or component failure, and cabin equipment and furniture must remain operational.
Ensures equipment won’t ignite flammable vapours.
Example: Fuel tank sensors must not produce sparks or heat that could ignite fuel-air mixtures during refuelling.
Tests resistance to water ingress from rain, spray, or condensation.
Example: External lighting systems on aircraft wings must remain sealed against rain and de-icing fluid during flight.
Assesses resistance to aviation fluids like hydraulic oil, fuel, and cleaning agents.
Example: Landing gear sensors may be exposed to hydraulic fluid leaks and must continue to function without degradation.
Tests for operation in dusty or sandy environments.
Example: Aircraft operating in desert regions must have sensors that resist clogging or abrasion from airborne particles.
Ensures materials don’t degrade when certain mould and fungus grows in the corresponding environments.
Example: Wiring insulation in cargo holds must resist fungal growth that could compromise electrical integrity.
Tests corrosion resistance in marine or coastal environments.
Example: Aircraft electronics must withstand salt-laden air that can corrode connectors and circuit boards.
Assesses performance when exposed to ice buildup.
Example: Actuators and external sensors must remain functional even when exposed to freezing rain or high-altitude icing conditions.
Ensures materials won’t propagate fire or emit toxic smoke.
Example: Cabin displays and insulation must meet flammability standards to protect passengers during onboard fires.
Tests for magnetic interference with sensitive instruments.
Example: A power supply unit installed near a magnetic compass must not distort compass readings.
Verifies operation under voltage and frequency variations.
Example: Avionics must tolerate power fluctuations during engine start-up or generator switching without rebooting.
Tests resistance to sudden voltage surges.
Example: A lightning strike near the aircraft can induce voltage spikes that must not damage flight control computers.
Assesses susceptibility to low-frequency noise on power lines.
Example: Cabin lighting systems must not flicker or malfunction due to interference from onboard audio systems.
Tests for electromagnetic coupling from nearby wiring.
Example: Long cable runs near high-power radar systems must not pick up noise that affects signal integrity.
Ensures immunity to radio frequency interference.
Example: Communication systems must operate reliably even when exposed to high-power radar or satellite uplinks.
Measures emissions to prevent interference with other systems.
Example: A flight management system must not emit RF noise that disrupts GPS or cockpit radios.
Simulates indirect lightning effects on wiring.
Example: A lightning strike near the aircraft can induce transients in wiring harnesses that must not affect avionics.
Tests for direct lightning strikes on external components.
Example: Wingtip-mounted antennas must survive a direct strike without catastrophic failure.
Assesses resistance to static electricity discharges.
Example: Maintenance personnel touching exposed connectors must not cause system resets or damage due to static discharge.
Enhancing development with pre-compliance testing
Before initiating full compliance testing, incorporating pre-compliance testing can be a strategic advantage. By focusing on a subset of the more challenging tests early in the development cycle, teams can identify and resolve potential issues proactively. This approach not only streamlines the path to full compliance but also reduces the risk of delays and costly rework during the formal testing phase.
Our state-of-the-art UK testing lab is equipped with the latest environmental simulation technology, and our experienced engineers ensure accurate, efficient, and fully documented testing.
| Accredited lab – ISO/IEC 17025 certified | |
| Speedy quotes - Assess your budget against test costs early to build a robust business case | |
| Fast turnaround – Flexible scheduling and rapid reporting | |
| Expert support – Guidance through the entire compliance process | |
| Custom test plans – Tailored to your product and certification needs |
Whether you're developing a new avionics system or need to requalify existing airborne equipment, we’re here to help. Contact our RTCA DO-160 experts today to discuss your project or request a quote.
The “DO” in DO-160 stands for “Document.” It is a designation used by RTCA to label its published standards, with DO-160 specifically referring to the environmental conditions and test procedures for airborne equipment.
The current version of DO-160 is DO-160G with Change 1, published in December 2014. This version includes updated procedures and requirements for environmental testing of airborne equipment, reflecting advancements in technology and regulatory expectations.
DO-160 is not legally mandatory by itself, but compliance is effectively required because aviation authorities like the FAA and EASA use it to assess equipment for certification. Meeting DO-160 standards is essential for installing avionics in commercial and military aircraft.
DO-160 testing typically takes 4 to 12 weeks, depending on the number of test categories, equipment complexity, and test lab scheduling. More extensive testing across all sections or required re-tests can extend the timeline beyond 12 weeks.
The main difference between DO-160 and MIL-STD-810 is that DO-160 applies to commercial aviation equipment, while MIL-STD-810 is used for military systems. DO-160 focuses on standardised environmental tests for avionics, whereas MIL-STD-810 emphasises mission-specific testing for rugged military use.
The main difference between DO-160 and DO-178 is that DO-160 covers environmental testing for hardware, while DO-178 addresses software development and verification for airborne systems. DO-160 ensures equipment survives physical stress. DO-178 ensures software safety and reliability.
The main difference between DO-160 and DEF STAN 00-35 is that DO-160 specifies environmental and EMC testing for airborne equipment, while DEF STAN 00-35 specifies environmental testing only for military equipment and materials. For military equipment, EMC DEF STAN 59-411 must be used.
The European equivalent of DO-160 is EUROCAE ED-14. ED-14 is technically identical to DO-160 and is jointly developed by EUROCAE and RTCA. It serves as the accepted environmental testing standard for airborne equipment in Europe.
Determine test levels in RTCA DO-160 by identifying your product’s installation category, equipment class, and operational environment. Test levels vary across 23 sections, including vibration, temperature, and EMI. Coordination with certification authorities ensures correct levels based on aircraft type and equipment location.
Site Selector
Global
Americas
Asia
Europe
Middle East and Africa
