Aviation Cases: DO-160G, AS9100D, ATA 300

A Honeywell HGT-1000 inertial reference unit ($25,000-$40,000) shipped from an avionics OEM facility in Phoenix to an airline maintenance base in London arrived with a damaged accelerometer connector. The cause? A standard wooden crate with 25mm of loose-fill polystyrene that shifted during air freight, allowing the 5kg IRU to move 15mm inside the crate and impact the crate wall during a 12g handling drop at the airline maintenance base loading dock. The repair required a replacement accelerometer connector ($3,500), a full re-calibration of the IRU ($8,000 in engineering time), and a 2-day delay in the aircraft’s maintenance schedule. The aircraft’s delay cost was $25,000 per day (a typical commercial aircraft has $10,000-$50,000 per day in delay costs for maintenance downtime, including labor, equipment rental, and passenger service delays)—so the total cost of that damaged accelerometer connector was $61,500.

Aviation equipment spans the entire aircraft system: from glass cockpit display and flight deck equipment (primary flight displays, multi-function displays, engine indication displays, crew alerting systems, control display units, flight management systems, autopilot control panels, radio management panels, cockpit controllers, cockpit sensors) that provide cockpit display and flight deck capabilities, to flight management and navigation equipment (flight management computers, navigation computers, GPS receivers, inertial reference systems, air data computers, radio altimeters, distance measuring equipment, VOR receivers, ILS receivers, navigation controllers, navigation sensors) that provide flight management and navigation, to transponder, TCAS, and surveillance equipment (transponders, TCAS systems, ADS-B systems, weather radar systems, traffic advisory systems, surveillance controllers, surveillance sensors) that provide transponder, TCAS, and surveillance, to weather radar and communication equipment (weather radar systems, communication radios, satellite communication systems, HF radios, VHF radios, cabin communication systems, communication controllers, communication sensors) that provide weather radar and communication, to flight control and autopilot equipment (flight control computers, autopilot systems, yaw damper systems, stabilizer trim systems, flap control systems, slat control systems, spoiler control systems, flight control controllers, flight control sensors) that provide flight control and autopilot, to APU and engine components (APU controllers, engine controllers, fuel control units, ignition systems, engine sensors, APU sensors, engine actuators, APU actuators) that provide APU and engine capabilities. What unites them is that every piece of equipment is part of a system where a single failure can cause an aircraft grounding (which can cost $10,000-$100,000 per day for aircraft operations), a safety issue (from equipment malfunction, which can cause aviation accidents or aviation worker injury), or in extreme cases, an aviation equipment recall (which can cost $1,000,000-$100,000,000 for aviation equipment companies). The transit case isn’t packaging—it’s the first line of defense against equipment damage during transport, and it must be specified to the same engineering rigor as the equipment it protects.

Regulatory Framework: DO-160G, AS9100D, ATA 300, and Aviation Standards

Aviation equipment transport cases must support compliance with a complex web of standards. For environmental testing, DO-160G (Environmental Conditions and Test Procedures for Airborne Equipment) specifies environmental conditions and test procedures for airborne equipment, including temperature testing, humidity testing, vibration testing, shock testing, altitude testing, and salt mist testing, and the transit case must protect aviation equipment without compromising its environmental features (including temperature resistance, humidity resistance, vibration resistance, shock resistance, altitude resistance, and salt mist resistance). For aviation equipment quality, AS9100D (Quality Management Systems—Requirements for Aviation, Space and Defense Organizations) specifies quality management system requirements for aviation, space and defense organizations, and the transit case must support the quality management requirements of aviation equipment (including quality records, quality documentation, and quality traceability). For aviation packaging, ATA 300 (Packaging of Airline Supplies and Equipment) specifies packaging of airline supplies and equipment requirements, and the transit case must meet the packaging requirements of aviation equipment (including packaging design, packaging testing, and packaging documentation).

For aviation equipment EMC (Electromagnetic Compatibility), DO-160G Section 20 (Radio Frequency Susceptibility) specifies radio frequency susceptibility requirements for airborne equipment, and the transit case must protect EMC-sensitive aviation equipment without compromising its EMC features (including electromagnetic shielding, electromagnetic filtering, and electromagnetic grounding). For aviation equipment ESD (Electrostatic Discharge), DO-160G Section 25 (Electrostatic Discharge) specifies electrostatic discharge requirements for airborne equipment, and the transit case must protect ESD-sensitive aviation equipment without compromising its ESD features (including ESD-safe materials, ESD-safe packaging, and ESD-safe handling). For aviation equipment safety, ARP 4754A (Guidelines for Development of Civil Aircraft and Systems) specifies guidelines for development of civil aircraft and systems, and the transit case must protect safety-related aviation equipment without compromising its safety features (including safety integrity, safety reliability, and safety availability). For aviation equipment software, DO-178C (Software Considerations in Airborne Systems and Equipment Certification) specifies software considerations in airborne systems and equipment certification, and the transit case must protect software-controlled aviation equipment without compromising its software features (including software integrity, software reliability, and software availability). For aviation equipment hardware, DO-254 (Design Assurance Guidance for Airborne Electronic Hardware) specifies design assurance guidance for airborne electronic hardware, and the transit case must protect hardware-controlled aviation equipment without compromising its hardware features (including hardware integrity, hardware reliability, and hardware availability). For aviation equipment testing, DO-160G (Environmental Conditions and Test Procedures for Airborne Equipment) specifies environmental testing for airborne equipment, and the transit case must support the testing requirements of aviation equipment (including test records, test documentation, and test traceability).

Cockpit Displays, Navigation, and Surveillance: Core Equipment Transport

Glass cockpit display and flight deck equipment (primary flight displays, multi-function displays, engine indication displays, crew alerting systems, control display units, flight management systems, autopilot control panels, radio management panels, cockpit controllers, cockpit sensors) are typically shipped as complete units with precision components, electronics, connectors, and documentation. The most critical areas are: component protection (cockpit display components such as displays, control display units, and flight management systems can be damaged by impact or by vibration, causing component failure or cockpit equipment malfunction), connector protection (cockpit display connectors such as power connectors, data connectors, and signal connectors can be damaged by impact or by vibration, causing connection problems or equipment failure), and ESD-sensitive components (which can be damaged by electrostatic discharge as low as 50V). Our glass cockpit display and flight deck equipment cases use: component protection (custom foam with zero-contact foam on components, and custom component protectors to prevent damage), connector protection (custom foam with zero-contact foam on connectors, and custom connector protectors to prevent damage), ESD-safe foam (surface resistance 10^6-10^9 Ω/sq) for all electronic components, vibration isolation (custom foam with vibration isolation properties, and custom vibration isolators to prevent component damage), and IP65 sealing (continuous silicone gaskets, for protection against dust and moisture during transport and storage at airline maintenance bases).

Flight management and navigation equipment (flight management computers, navigation computers, GPS receivers, inertial reference systems, air data computers, radio altimeters, distance measuring equipment, VOR receivers, ILS receivers, navigation controllers, navigation sensors) are typically shipped as complete units with precision components, electronics, connectors, and documentation. The most critical areas are: precision components (which can have tolerances of ±0.01mm, and must not be damaged by impact or by vibration, causing navigation errors or flight management errors), ESD-sensitive components (which can be damaged by electrostatic discharge as low as 50V), and calibration (flight management and navigation equipment requires precise calibration of navigation parameters, which can be affected by vibration during transport). Our flight management and navigation equipment cases use: precision component protection (custom foam with zero-contact foam on precision components, and custom component protectors to prevent damage), ESD-safe foam (surface resistance 10^6-10^9 Ω/sq) for all electronic components, calibration protection (custom foam that holds each component in its calibrated position, with zero-contact foam on all precision adjustment mechanisms), vibration isolation (custom foam with vibration isolation properties, and custom vibration isolators to prevent component damage), and IP65 sealing (continuous silicone gaskets, for protection against dust and moisture during transport and storage at airline maintenance bases). Transponder, TCAS, and surveillance equipment (transponders, TCAS systems, ADS-B systems, weather radar systems, traffic advisory systems, surveillance controllers, surveillance sensors) are typically shipped as complete units with precision components, electronics, connectors, and documentation. The most critical areas are: component protection (transponder and TCAS components such as transponders, TCAS systems, and ADS-B systems can be damaged by impact or by vibration, causing component failure or surveillance equipment malfunction), connector protection (transponder and TCAS connectors such as antenna connectors, power connectors, and data connectors can be damaged by impact or by vibration, causing connection problems or equipment failure), and ESD-sensitive components (which can be damaged by electrostatic discharge as low as 50V). Our transponder, TCAS, and surveillance equipment cases use: component protection (custom foam with zero-contact foam on components, and custom component protectors to prevent damage), connector protection (custom foam with zero-contact foam on connectors, and custom connector protectors to prevent damage), ESD-safe foam (surface resistance 10^6-10^9 Ω/sq) for all electronic components, vibration isolation (custom foam with vibration isolation properties, and custom vibration isolators to prevent component damage), and IP65 sealing (continuous silicone gaskets, for protection against dust and moisture during transport and storage at airline maintenance bases).

Communication, Flight Control, and Engine: Specialized Transport Requirements

Weather radar and communication equipment (weather radar systems, communication radios, satellite communication systems, HF radios, VHF radios, cabin communication systems, communication controllers, communication sensors) are typically shipped as complete units with precision components, electronics, connectors, and documentation. The most critical areas are: component protection (weather radar and communication components such as weather radar systems, communication radios, and satellite communication systems can be damaged by impact or by vibration, causing component failure or communication equipment malfunction), connector protection (weather radar and communication connectors such as antenna connectors, power connectors, and data connectors can be damaged by impact or by vibration, causing connection problems or equipment failure), and ESD-sensitive components (which can be damaged by electrostatic discharge as low as 50V). Our weather radar and communication equipment cases use: component protection (custom foam with zero-contact foam on components, and custom component protectors to prevent damage), connector protection (custom foam with zero-contact foam on connectors, and custom connector protectors to prevent damage), ESD-safe foam (surface resistance 10^6-10^9 Ω/sq) for all electronic components, vibration isolation (custom foam with vibration isolation properties, and custom vibration isolators to prevent component damage), and IP65 sealing (continuous silicone gaskets, for protection against dust and moisture during transport and storage at airline maintenance bases).

Flight control and autopilot equipment (flight control computers, autopilot systems, yaw damper systems, stabilizer trim systems, flap control systems, slat control systems, spoiler control systems, flight control controllers, flight control sensors) are typically shipped as complete units with precision components, electronics, connectors, and documentation. The most critical areas are: precision components (which can have tolerances of ±0.01mm, and must not be damaged by impact or by vibration, causing flight control errors or autopilot errors), ESD-sensitive components (which can be damaged by electrostatic discharge as low as 50V), and calibration (flight control and autopilot equipment requires precise calibration of flight control parameters, which can be affected by vibration during transport). Our flight control and autopilot equipment cases use: precision component protection (custom foam with zero-contact foam on precision components, and custom component protectors to prevent damage), ESD-safe foam (surface resistance 10^6-10^9 Ω/sq) for all electronic components, calibration protection (custom foam that holds each component in its calibrated position, with zero-contact foam on all precision adjustment mechanisms), vibration isolation (custom foam with vibration isolation properties, and custom vibration isolators to prevent component damage), and IP65 sealing (continuous silicone gaskets, for protection against dust and moisture during transport and storage at airline maintenance bases). APU and engine components (APU controllers, engine controllers, fuel control units, ignition systems, engine sensors, APU sensors, engine actuators, APU actuators) are typically shipped as complete units with precision components, electronics, connectors, and documentation. The most critical areas are: component protection (APU and engine components such as APU controllers, engine controllers, and fuel control units can be damaged by impact or by vibration, causing component failure or engine equipment malfunction), connector protection (APU and engine connectors such as power connectors, data connectors, and signal connectors can be damaged by impact or by vibration, causing connection problems or equipment failure), and vibration isolation (APU and engine components can be damaged by vibration during transport, which can cause internal component damage or equipment malfunction). Our APU and engine component cases use: component protection (custom foam with zero-contact foam on components, and custom component protectors to prevent damage), connector protection (custom foam with zero-contact foam on connectors, and custom connector protectors to prevent damage), vibration isolation (custom foam with vibration isolation properties, and custom vibration isolators to prevent component damage), and IP65 sealing (continuous silicone gaskets, for protection against dust and moisture during transport and storage at airline maintenance bases).

Case Design Specifications and OEM/ODM Capabilities

Our standard aviation equipment case specification includes: 2mm thick 5052-H32 aluminum panels (or 3mm for heavy-duty applications over 50kg payload, or 4mm for engine components that must meet structural requirements), Type II anodized (15-25μm) plus polyester TGIC powder coating (60-80μm) in matte black, gray, or custom color; continuous silicone gaskets (Shore A 50-60) providing IP65 sealing (IP67 available as option, for outdoor aviation applications); 304 or 316 stainless steel hardware (latches, hinges, handles, rivets)—316 stainless steel is preferred for outdoor aviation applications, as it is more corrosion-resistant; CNC-cut closed-cell XLPE foam (40-80 kg/m³, customer-specified density based on payload weight and fragility) with ESD-safe option (surface resistance 10^6-10^9 Ω/sq); heavy-duty draw latches (Southco or equivalent) with rubber bumpers; folding side handles (for cases over 15kg) or top handle (for cases under 15kg); stacking corners (recessed, for secure stacking); and a waterproof document holder (A4 size, inside lid).

Every aviation equipment case we build is custom-sized to your equipment’s exact dimensions, with CNC-cut foam cavities that hold each component in its operational orientation. We don’t sell stock cases for aviation equipment—because a 5mm gap means 5mm of potential movement during transport, and that’s where component damage, connector damage, and ESD damage start. Typical lead time is 15-25 working days for first article (including design, prototyping, and customer approval), then 20-30 working days for production batches of 10-100 units. MOQ is 5 units per design. Pricing depends on size, complexity, and certification requirements. A typical communication radio case (300×200×150mm, 3kg payload, component protection, connector protection, ESD-safe foam, vibration isolation, IP65) ranges from $100-$180 FOB Changzhou. A typical primary flight display case (400×300×200mm, 8kg payload, component protection, connector protection, ESD-safe foam, vibration isolation, IP65) ranges from $180-$300 FOB. A typical flight management computer case (600×400×300mm, 20kg payload, precision component protection, calibration protection, ESD-safe foam, vibration isolation, IP65) ranges from $350-$550 FOB. A typical engine controller case (1000×800×600mm, 60kg payload, component protection, connector protection, vibration isolation, shock-isolated sub-crate, IP65) ranges from $700-$1,000 FOB. Volume discounts of 15-25% apply for orders over 50 units.