Modern military and aerospace supply chain management is facing greater challenges than ever before. Systems require longer development times and have longer production lifecycles than any other industry, often exceeding 30 years.
Additionally, the rapid advancements in semiconductor technology have accelerated the rate of component obsolescence. When faced with EOL critical parts, manufacturers must find reliable replacements, which not only cover single-replacement events, but also the requirements of a programme’s full lifecycle.
To support product transfer and licensed manufacturing of semiconductor components, Rochester Electronics has developed a state-of-the-art test and manufacturing facility at its headquarters in Newburyport, Massachusetts. Rochester can perform hermetic and plastic packaging, as well as complex hybrid assembly. In addition, Rochester has two US-based design centres with substantial silicon ASIC design experience, with a focus on original device replication and form-fit, functional drop-in product replacements.
Beyond providing long-term sourcing of obsolete devices, Rochester Electronics is successful in providing replicated alternatives that meet the exact performance specifications of the original device. These product replications differ from alternatives based on emulations, which attempt to mimic the functionality of the original device. Product replication includes working with the Original Component Manufacturer (OCM) and is an exact physical and electrical duplicate with output edge-rate matching. The product’s pin-for-pin construction, identical die size, and matched cycle-for-cycle timing mean the component is 100% guaranteed to perform identically to the original device. Product qualification of a duplicated device is significantly less than any redesigned or emulated alternative.
Obsolescence management for military applications
Aviation customers have partnered with Rochester to avoid the costly DO-254 recertification path by replicating devices that allow for simpler minor-change classification. Rochester’s team has enabled customers to migrate FPGA, PLD, and other programmable solutions into sourceable products for the life of their product lines.
Rochester has over 30,000 square feet dedicated to semiconductor test and burn-in, which includes 16 major ATE platforms, and over 40 testers and component handlers. The mix of both modern and legacy platforms empowers Rochester to provide a migration path that ensures continuity of product supply for many years to come.
While many vendors in the industry are phasing out lead-frame packages, Rochester continues to invest in a range of options, such as QFNs, PLCCs, QFPs, PDIPs, TSSOPs, and SOICs. We also support a wide range of standard hermetic assemblies. Full MIL-STD qualifications are completed within the Newburyport, Massachusetts facility. The reliability lab is certified by the Defence Logistics Agency to provide Group A, B, C, and D testing to military standards, including space level.
An aerospace and defence technology company recently partnered with Rochester Electronics for assembly services to support their hybrid-assembly circuit production. Specialised high-frequency assembly and test support, based in the United States with ITAR compliance, was required to ensure programme continuity. The custom military hybrid module was originally designed in the 1970s to support active government programmes, and the Original Equipment Manufacturer of the original hybrid product was no longer supporting new builds. Rochester is providing full manufacturing support for the hybrid assembly, including hermetic package assembly, device integration, electrical testing, and full qualification to the original specification. The product is now in full production. Rochester Electronics was the programme’s ideal partner, not only because of experienced manufacturing skills, but also the necessary levels of component inventory needed for an ongoing ITAR-certified programme. The customer was saved from significant redesign and requalification costs and maintained its reputation as a key US government supplier.
Rochester Electronics is a reliable longterm US-based partner to the military and aerospace industries. For more than three decades we have been enabling product transfers and helping our customers avoid component obsolescence. We continue to invest in onshore Design, Manufacturing, and Test services to ensure the continuity of semiconductor product supply. We are committed to providing our customers with a continuous source of supply and extending product lifecycles.
Find out more – www.rocelec.com
This article originally appeared in the September’25 magazine issue of Electronic Specifier Design – see ES’s Magazine Archives for more featured publications.
