RTCA DO-160 - Aerospace environmental testing

RTCA DO-160 is an EMC and environmental 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 and electromagnetic conditions they’ll face in flight such as temperature extremes, altitude, vibration, shock, humidity, lightning, EMI and EMC performance. DO-160 is widely used by authorities such as UK CAA, FAA, EASA and Transport Canada to support certification and airborne equipment compliance for commercial and defense aircraft.

We offer comprehensive environmental testing services in the US across multiple DO-160 sections, including some of the following tests:

Environmental & mechanical testing

Section 4 – Temperature and altitude testing

Simulates high-altitude and extreme temperature conditions.

Example: Avionics equipment installed in the unpressurized section of a commercial aircraft must operate reliably at -55°C and altitudes up to 50,000 ft, where low air pressure and reduced cooling can affect critical systems performance.

Section 5 – Temperature variation testing

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.

Section 6 – Humidity testing

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.

Section 7 – Operational shock and crash safety testing

Simulates mechanical shocks from rough landings or crash impacts.

Example: After a crash, emergency location transmitters (ELT) must remain functional to transmit location data to search & rescue teams. Other critical cabin equipment must remain securely mounted and safe.

Section 8 – Vibration testing

Tests for continuous standard, high-level or robust vibration levels 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.

Environmental exposure testing

Section 9 – Explosion atmosphere testing

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.

Section 10 – Waterproofness testing

These tests determine whether the equipment can withstand the effects of liquid water being sprayed or falling on the equipment or the effects of condensation.

Example: External lighting systems on aircraft wings must remain sealed against rain, ice crystals and de-icing fluid during flight.

Section 11 – Fluids susceptibility testing

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.

Section 12 – Sand and dust testing

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.

Section 13 – Fungus resistance testing

These tests determine whether equipment material is adversely affected by fungi under conditions favorable for their development, namely, high humidity, warm atmosphere and presence of inorganic salts.

Example: Wiring insulation in cargo holds must resist fungal growth that could compromise electrical integrity.

Section 14 – Salt fog testing

Tests corrosion resistance in marine or coastal environments.

Example: Aircraft electronics must withstand salt-laden air that can corrode connectors and circuit boards.

Find out more about Standard Practice for Operating Salt Spray (Fog) Apparatus on the ASTM website.

EMC & electrical testing

Section 15 – Magnetic effect

Tests for magnetic interference with sensitive instruments.

Example: A power supply unit installed near a magnetic compass must not distort compass readings.

Section 16 – Power input testing

Verifies operation under voltage and frequency variations.

Example: Critical avionics systems must tolerate power fluctuations during engine start-up or generator switching without rebooting.

Section 17 – Voltage spike testing

Tests resistance to sudden voltage surges.

Example: A lightning strike near the aircraft can induce voltage spikes that must not damage flight control computers.

Section 18 – Audio frequency conducted susceptibility testing

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.

Section 19 – Induced signal susceptibility testing

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.

Section 20 – RF susceptibility (radiated and conducted) testing

Ensures immunity to radio frequency interference.

Example: Communication systems must operate reliably even when exposed to high-power radar or satellite uplinks.

Section 21 – RF emissions testing

Measures emissions to prevent interference with other systems.

Example: A flight management system must not emit RF noise that disrupts GPS or VHF radios.

Section 25 – Electrostatic discharge (ESD) testing

Assesses resistance to static electricity discharges.

Example: Maintenance personnel touching exposed connectors must not cause system resets or damage due to static discharge.

Lightning & safety testing

Section 22 – (Indirect) Lightning Induced Transient Susceptibility Testing

Simulates indirect lightning effects on wiring and is used for internally mounted electronics and systems.

Example: A lightning strike near the aircraft can induce transients in wiring harnesses that must not affect avionics systems. 

Section 23 – Lightning direct effects testing

Tests for direct lightning strikes on external components and equipment located on the exterior of the aircraft (antennas, etc).

Example: Wingtip-mounted antennas must survive a direct strike without catastrophic failure.

Before starting full compliance testing, completing pre-compliance testing can offer 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 streamlines the path to full compliance and reduces the risk of delays and costly rework during the formal testing phase. Contact our experts to discuss how pre-compliance testing can save you time and money.

• Aircraft OEMs and systems integrators – Qualify mechanical, electrical and electromechanical systems for installation on commercial, business and Advanced Air Mobility (AAM) aircraft.
• Equipment and component manufacturers – Demonstrate compliance of airborne equipment, components and assemblies with environmental, EMC and RF requirements.
• Tier 1 and Tier 2 aerospace suppliers – Generate qualification evidence for systems and subsystems supporting aircraft certification and customer qualification programmes.
• UAV/drone developers – Verify the safety, performance, and durability of unmanned aircraft systems operating in demanding environments.
• Defense contractors – Qualify airborne and mission-critical equipment to meet rigorous defence and operational requirements.

1. Test plan development

Define the applicable DO-160 test categories, operating conditions, and pass/fail criteria to create a test plan tailored to your equipment and certification requirements.

2. Environmental and EMC testing

Evaluate mechanical, electrical and electronic airborne equipment under simulated operational environments to demonstrate compliance with RTCA DO-160 environmental and electromagnetic requirements.

3. Reporting and certification support

Receive a detailed test report documenting evidence that the equipment complies with the applicable sections and categories to support certification and regulatory approval.

RTCA DO-160 testing is offered from our global network of laboratories including across North America, the UK, Central Europe and Asia.