DO-160 FAQs

What Is DO-160 and Why Is it Important?

DO-160, also known as RTCA DO-160, is a standard that specifies environmental conditions and test procedures for avionics equipment intended for use in civil aviation. It was developed by RTCA, Inc., an organization that provides recommendations for aviation-related technologies. The standard outlines a set of environmental conditions—such as temperature, humidity, vibration, shock, and electromagnetic interference—that avionics equipment must be able to withstand in order to ensure safe and reliable operation under a wide range of conditions.

Why is DO-160 important?

1. Safety and Reliability: DO-160 ensures that avionics equipment can function reliably and safely under various environmental conditions encountered in aviation, such as extreme temperatures, electromagnetic interference, or turbulence.
2. Regulatory Compliance: Compliance with DO-160 is required by aviation regulatory bodies like the Federal Aviation Administration (FAA) and European Union Aviation Safety Agency (EASA) for avionics certification. This ensures that the equipment meets the required standards for airworthiness.
3. Global Standardization: The standard is recognized worldwide, ensuring that avionics manufacturers adhere to the same testing procedures and requirements, which simplifies certification and enhances global market access.
4. Quality Assurance: By following DO-160, manufacturers demonstrate their commitment to producing high-quality, reliable equipment. It serves as a benchmark for ensuring that equipment can withstand harsh conditions during operation in the aviation environment.

In summary, DO-160 plays a crucial role in maintaining safety, regulatory compliance, and consistency across the aviation industry by setting clear, standardized testing procedures for avionics equipment.

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What is the latest itineration of DO-160?

The latest iteration of the DO-160 standard is Revision G, published in December 2010. This revision introduced updates to test conditions, power input, and susceptibility to radio frequencies, among other factors.

Currently, a new revision, DO-160H, is under development, with a target publication date of March 2026.

What Are the Key Components of DO-160?

DO-160, titled “Environmental Conditions and Test Procedures for Airborne Equipment,” provides a comprehensive set of guidelines for testing the environmental conditions that avionics equipment may experience during operation. The key components of DO-160 include:

1. Environmental Conditions:
   • DO-160 defines various environmental factors that airborne equipment must withstand, such as temperature, pressure, humidity, altitude, and vibration.
   • The standard categorizes these conditions into different levels (e.g., Category A for more stringent conditions and Category B for less severe conditions) to suit various aircraft types and operational environments.
2. Test Procedures:
   • Detailed test procedures are outlined to verify that equipment performs as expected under each environmental condition.
   • These tests are conducted under controlled conditions, using equipment such as thermal chambers, vibration machines, and power supplies to simulate different environmental factors.
3. Power Input and Characteristics:
   • DO-160 specifies the requirements for the power input, including voltage, current, and frequency ranges, as well as the ability to withstand power fluctuations, surges, and transients.
   • This ensures that avionics equipment can handle power variations and continue to function reliably.
4. Radio Frequency Susceptibility and Emissions:
   • The standard includes requirements to assess the equipment’s immunity to radio frequency interference (RFI) and its ability to emit radio frequencies within acceptable limits (EMC – electromagnetic compatibility).
   • Equipment must be tested for both immunity to external RF signals and its own emissions to avoid interference with other systems.
5. Mechanical Vibration and Shock:
   • Tests are included to verify that equipment can handle mechanical shocks and vibrations experienced during flight, such as turbulence, landing, or sudden movements.
   • These tests assess the resilience of the equipment’s mechanical components and ensure that it remains operational under physical stress.
6. Temperature and Humidity:
   • DO-160 provides detailed procedures for testing the equipment’s ability to function under extreme temperature and humidity conditions.
   • This ensures that the equipment can operate in various climates, from freezing temperatures at high altitudes to hot, humid environments.
7. Altitude and Pressure:
   • The standard requires testing for equipment performance at different altitudes and corresponding pressure levels, including reduced air pressure that may be encountered during flight.
   • The equipment must continue to perform properly in conditions such as low oxygen levels or rapid cabin decompression.
8. Sustainability and Lifespan:
   • Some tests assess the long-term durability of the equipment, ensuring that it can operate over extended periods and withstand aging factors like wear and tear, oxidation, or material fatigue.
9. Electromagnetic Interference (EMI) and Lightning Protection:
   • DO-160 includes tests to ensure that equipment can withstand electromagnetic disturbances and lightning strikes, crucial for avionics systems that operate in an electrically active environment.
10. Additional Special Conditions:
    • DO-160 accounts for specific situations, such as equipment used in special operational environments (e.g., high-speed aircraft, spacecraft, or helicopters), with additional guidelines to address these unique conditions.

These components are organized into 24 sections in the standard, with each addressing a different aspect of equipment testing and certification. The tests defined by DO-160 help ensure that avionics systems are reliable, robust, and safe for use in the demanding environment of modern aircraft.

How Is DO-160 Implemented?

The implementation of DO-160 involves several key stages to ensure avionics equipment meets the environmental testing standards specified by the document. Here’s how it is typically implemented:

1. Design Phase

• Specification Review: During the design phase, the engineers and designers of avionics systems review the relevant sections of DO-160 that apply to their specific equipment. They need to understand the environmental conditions it will be exposed to and ensure that the system design accounts for these factors.
• Environmental Considerations: Design considerations are made based on the equipment’s operational environment, including temperature, humidity, vibration, pressure, and other conditions outlined in the DO-160 standard. The design is adapted to meet the specific requirements of the intended aircraft or use case.

2. Test Plan Development

• Test Definition: A test plan is developed to define the specific DO-160 tests that need to be performed on the equipment. This plan identifies the levels of environmental conditions (e.g., temperature, altitude) that the equipment will be subjected to.
• Test Setup Design: The necessary test setups are created, which involve setting up the testing equipment such as thermal chambers, vibration tables, and power supplies, in alignment with the procedures outlined in DO-160.
• Test Levels Selection: The test levels for each environmental condition (e.g., temperature ranges, vibration levels) are selected based on the aircraft type and operational environment. The tests can range from the most extreme conditions (for commercial jetliners) to less severe conditions (for smaller aircraft or ground-based systems).

3. Pre-Testing and Simulation

• Simulation: Before actual physical testing, some environmental conditions may be simulated using computer modeling and simulations to predict the equipment’s performance in various scenarios. This helps identify potential issues and refine the design before costly physical testing.
• Pre-test Checks: Engineers ensure that the equipment is ready for testing by performing initial checks for functionality and confirming that the correct hardware and software versions are in place.

4. Testing and Data Collection

• Environmental Tests: The equipment undergoes the specific environmental tests described in DO-160. This could include:
  • Temperature and Humidity Tests: Subjecting the equipment to varying levels of heat, cold, and humidity.
  • Vibration and Shock Tests: Exposing the equipment to mechanical vibration and shock to simulate conditions like turbulence or hard landings.
  • Altitude Tests: Testing the equipment at high altitudes and low-pressure environments to mimic conditions found at cruising altitudes.
  • Radio Frequency Susceptibility and Emission Tests: Ensuring the equipment can handle electromagnetic interference and that it does not emit excessive interference.
• Test Equipment: Specialized test equipment is used to simulate environmental conditions and measure how the avionics equipment responds.

5. Evaluation of Results

• Performance Verification: After the tests, the performance of the equipment is evaluated to see if it meets the criteria outlined in DO-160. Any deviations from the specified limits are noted, and adjustments are made.
• Documentation: Test results are documented in detail, including test conditions, any failures, corrective actions taken, and the final results.

6. Certification

• Report Compilation: A comprehensive test report is compiled based on the results, detailing the procedures followed, the equipment performance, and any deviations. This report must meet the documentation standards for certification.
• Certification Submission: The test results and associated documentation are submitted to relevant certification authorities (such as the FAA or EASA) for approval. This is a crucial step in obtaining the necessary certification for the equipment’s use in the aviation industry.
• Final Certification: If the equipment passes the tests and meets the applicable requirements, it is granted certification by the relevant authorities, signifying that it is ready for operational use.

7. Post-Certification Monitoring

• Ongoing Monitoring and Updates: After certification, the equipment must continue to be monitored for any potential environmental issues during its operational life. Any changes to the equipment (such as upgrades or changes to its operating environment) may require additional testing to ensure continued compliance with DO-160.
• Re-qualification: If the equipment undergoes significant modifications, or if there are changes to operational environments (e.g., new aircraft models or updated regulations), the equipment may need to go through a re-qualification process under DO-160 to ensure it still meets all required conditions.

8. Compliance with DO-160 Subsections

• Subsection Testing: DO-160 is divided into several sections (24 in total), each covering a different environmental condition or test. These include:
  • Section 1: General Introduction
  • Section 2: Temperature and Humidity
  • Section 3: Altitude and Pressure
  • Section 4: Power Input
  • Section 5: Radio Frequency Susceptibility
  • Section 6: Vibration and Shock, etc.
• Each section must be complied with in full or in accordance with the specific type of equipment and its intended use.

Summary

Implementing DO-160 involves careful design and rigorous testing to ensure that avionics equipment can handle the wide range of environmental conditions encountered in aviation. The testing must be thorough and methodical, covering all aspects of the equipment’s functionality, durability, and resilience. Successful completion of these tests, combined with thorough documentation and certification, results in a reliable and compliant avionics system that can be safely used in the aviation industry.

What Technologies and Tools Are Used in DO-160?

The implementation of DO-160 involves the use of several technologies and tools to simulate and measure environmental conditions that avionics equipment must endure. These tools ensure that the equipment meets the rigorous standards set forth in the DO-160 guidelines. Below are the key technologies and tools used in DO-160 testing:

1. Thermal Chambers

• Purpose: Thermal chambers (also known as environmental chambers or ovens) are used to simulate extreme temperature conditions that avionics equipment might encounter during operation, such as freezing cold at high altitudes or excessive heat during ground operation.
• Technology: These chambers control temperature within a wide range, often from -55°C to +85°C or higher, depending on the equipment’s specifications.
• Example Tools:
  • ThermoTech Environmental Chambers
  • Espec Environmental Test Chambers
  • Weiss Technik Chambers

2. Vibration and Shock Test Systems

• Purpose: Vibration and shock testing simulates the mechanical stresses and forces experienced during turbulence, takeoff, landing, or accidents. These tests are crucial for ensuring the mechanical durability of avionics equipment.
• Technology: Vibration test systems use electrodynamic shakers, while shock tests may use drop tables or pendulum systems. The equipment is subjected to sinusoidal, random, or shock pulses according to DO-160 standards.
• Example Tools:
  • Thermotron Vibration Test Systems
  • Unholtz-Dickie Vibration Shakers
  • Laboratory Environmental Systems (LES) Vibration Tables

3. Altitude Chambers

• Purpose: These chambers simulate high-altitude conditions, where lower air pressure and oxygen levels can affect equipment performance. Altitude chambers help test avionics for air pressure fluctuations, including those encountered during flight and decompression.
• Technology: Altitude chambers use a vacuum pump or pressure control systems to simulate altitude up to 100,000 feet. The equipment is tested for functionality in both reduced and increased pressure environments.
• Example Tools:
  • Espec Altitude Chambers
  • Ametek Altitude Simulators

4. Power Supplies and Testing Systems

• Purpose: Power input tests ensure that the equipment can handle fluctuations in voltage, current, and frequency, which may occur during flight. DO-160 requires the equipment to withstand power surges, dips, and transients.
• Technology: Precision programmable power supplies and electrical load simulators are used to test the power input conditions as specified by DO-160.
• Example Tools:
  • Keysight Technologies Power Supplies
  • Chroma Programmable Power Sources
  • Teseq Immunity Test Systems

5. Radio Frequency (RF) Test Systems

• Purpose: DO-160 includes testing for radio frequency susceptibility and emissions. RF susceptibility tests ensure that equipment remains functional in the presence of electromagnetic interference (EMI), while RF emissions tests ensure that equipment does not emit harmful interference.
• Technology: RF generators, field probes, and anechoic chambers are used to simulate radio frequency signals and measure the equipment’s response. These systems can test for a wide range of frequencies and simulate various levels of electromagnetic interference.
• Example Tools:
  • Rohde & Schwarz EMC Test Systems
  • EM Test RF Chambers
  • ETS-Lindgren Anechoic Chambers

6. Electromagnetic Interference (EMI) Test Systems

• Purpose: EMI test systems are used to assess the potential electromagnetic interference (EMI) generated by equipment and its immunity to external EMI. Ensuring that avionics systems do not emit excessive EMI or become susceptible to external sources is vital for safe aircraft operation.
• Technology: EMI chambers, signal analyzers, and measurement receivers are used to measure the EMI emitted by the equipment and verify compliance with the EMC requirements specified in DO-160.
• Example Tools:
  • Rohde & Schwarz Signal Analyzers
  • Keysight Technologies EMI Receivers
  • Antenna Systems for EMI Testing

7. Humidity Chambers

• Purpose: Humidity chambers simulate various humidity levels and cycles, testing whether equipment can withstand moisture, condensation, or other forms of environmental moisture that may affect its function.
• Technology: These chambers are equipped with sensors to control and monitor relative humidity and can simulate conditions ranging from dry to extremely wet environments.
• Example Tools:
  • Binder Humidity Test Chambers
  • Weiss Technik Humidity Chambers

8. Lightning Strike Simulation Equipment

• Purpose: DO-160 includes tests for lightning susceptibility and direct strike simulations. Equipment must be able to withstand the effects of lightning, including direct strikes, induced voltages, and electromagnetic pulses (EMP).
• Technology: Lightning simulation systems use high-voltage generators to simulate lightning strikes, while current clamps and surge generators test the equipment’s response to induced currents.
• Example Tools:
  • EM Test Lightning Surge Generators
  • Teseq Lightning Simulation Systems

9. Data Logging and Monitoring Systems

• Purpose: During testing, various data points (e.g., temperature, pressure, power levels, vibration levels) need to be continuously monitored and logged to ensure that the equipment operates within the specified limits.
• Technology: Advanced data acquisition systems (DAQs) and monitoring software collect and display data in real time, allowing test engineers to assess equipment performance and identify failures or deviations.
• Example Tools:
  • National Instruments DAQ Systems
  • Keysight Data Acquisition Systems

10. Test Management Software

• Purpose: Test management software helps organize, track, and analyze the results of environmental tests, ensuring that all procedures are followed according to the DO-160 standards.
• Technology: These software systems integrate with test equipment and facilitate the creation of test reports, tracking failures, and maintaining compliance with certification bodies.
• Example Tools:
  • TestComplete
  • LabVIEW (National Instruments)

11. Anechoic Chambers

• Purpose: Used for electromagnetic testing, anechoic chambers are designed to create an environment free from external electromagnetic interference. They are often used in RF and EMI testing, as they prevent any external RF signals from affecting the tests.
• Technology: These chambers are lined with materials that absorb electromagnetic waves, creating a controlled environment for precise measurements of RF susceptibility and emissions.
• Example Tools:
  • ETS-Lindgren Anechoic Chambers
  • Cuming Microwave Anechoic Chambers

What Are Likely Future Trends of DO-160?

The future of DO-160 is likely to be influenced by several evolving trends in the aviation and avionics industries. These trends focus on the increasing complexity of technology, advancements in materials, and the push for greater environmental sustainability, safety, and interoperability. Here are some key trends that will likely shape the future iterations of DO-160:

1. Integration of New Technological Standards

• Emerging Technologies: As new technologies such as artificial intelligence (AI), machine learning (ML), and advanced sensor systems become integral to avionics equipment, DO-160 may need to adapt to ensure these systems are tested for robustness in various environments. The standard could incorporate new requirements for testing the performance and safety of AI-driven systems, autonomy, and real-time data processing.
• 5G and Next-Gen Communications: With the aviation industry moving toward faster communication technologies (e.g., 5G), DO-160 will likely evolve to include testing for new RF standards, interference issues, and communication resilience.

2. Increased Focus on Cybersecurity

• Cyber-Resilience: As avionics systems become more connected and integrated into broader networks (e.g., IoT, cloud systems), the importance of cybersecurity increases. DO-160 could expand to include requirements for testing the vulnerability of avionics systems to cyber threats, including hacking, data breaches, and unauthorized access to systems.
• Secure Software Updates: Future revisions may require testing procedures to ensure that software updates to avionics systems are secure, and they don’t introduce vulnerabilities or malfunctions during flight.

3. Enhanced Environmental Testing

• Sustainability and Green Technology: With the growing emphasis on reducing the carbon footprint of aviation, DO-160 could adapt to support the testing of eco-friendly technologies, such as hybrid-electric propulsion systems and energy-efficient avionics components. This could include testing for the impact of new battery technologies, renewable energy systems, or alternative fuel use on avionics hardware.
• More Detailed Climate Simulation: As global climates change, DO-160 may be updated to include more extreme environmental testing conditions, such as higher temperatures, humidity extremes, or tests for the impact of volcanic ash clouds, extreme wind speeds, or solar radiation.

4. More Comprehensive Testing for Autonomous and Unmanned Aircraft

• Autonomous Aircraft Systems: As the aviation industry moves toward greater levels of autonomy, DO-160 may need to incorporate specialized tests for autonomous systems, including those used in drones and urban air mobility (UAM) vehicles. These vehicles are subject to different operational conditions than traditional aircraft, and their avionics systems require unique testing for both functionality and safety.
• Urban Air Mobility (UAM) and Drone Integration: As drones and UAM systems become more prevalent, DO-160 might include testing for new environmental factors specific to these types of aircraft, such as low-altitude environmental conditions, high-frequency communication systems, and collision avoidance technologies.

5. Advanced Materials and Miniaturization

• Smaller, Lighter Avionics: The trend toward smaller, lighter avionics systems may lead to a need for different types of testing. New materials, such as lightweight composites or flexible electronics, may require unique testing methods to assess their durability under environmental stress.
• Flexible and Wearable Technologies: As wearable avionics or flexible displays become more common, DO-160 could incorporate tests that focus on these new forms of technology, such as flexing, folding, or bending during normal operation.

6. Improved Test Automation and Digital Twin Technology

• Automated Testing: The aviation industry’s push for increased efficiency and accuracy may lead to the adoption of automated testing systems that integrate real-time data acquisition and analysis. The use of AI and machine learning algorithms could help improve test scenarios and reduce human error.
• Digital Twin Technology: Digital twins—virtual representations of physical systems—are increasingly used to simulate real-world conditions and predict the behavior of complex systems. DO-160 could evolve to incorporate digital twin technology for more efficient testing, real-time monitoring, and predictive maintenance.

7. Adaptation to New Regulatory Frameworks

• Global Harmonization: As the aviation industry becomes more globalized, there may be a push toward harmonizing DO-160 with international standards (such as those from the European Union Aviation Safety Agency (EASA) or the International Civil Aviation Organization (ICAO)). Future revisions could focus on aligning DO-160 more closely with global safety and performance regulations.
• New Safety Regulations: With evolving safety concerns, future revisions of DO-160 could incorporate more stringent testing requirements, especially related to new risks such as electromagnetic pulse (EMP) and high-altitude EMP threats, or testing against cybersecurity vulnerabilities in connected avionics systems.

8. Integration with Predictive Maintenance Systems

• Maintenance-Ready Testing: The increasing use of predictive maintenance systems in aviation could lead to the development of new standards for testing avionics systems that monitor their own health and performance. DO-160 may be updated to ensure avionics systems are capable of detecting failures early and notifying maintenance teams in real-time.
• Real-Time Diagnostics: As avionics systems incorporate more diagnostic and health-monitoring features, future revisions of DO-160 could introduce testing procedures for self-diagnostic capabilities, ensuring equipment can perform in-flight monitoring and send alerts about potential malfunctions or degradation.

9. More Complex Interoperability Requirements

• Interoperability Testing for Multi-Vendor Systems: As avionics systems become more modular and integrated with systems from multiple vendors, DO-160 may introduce testing standards to verify the interoperability of these systems under various operational conditions. This will be critical in ensuring that equipment from different manufacturers can work seamlessly together without compromising safety or performance.
• Networking and System Integration: With the growing complexity of aircraft networks, including the integration of avionics with flight control systems, navigation, and communication systems, DO-160 may focus more on verifying the compatibility and integration of networked avionics systems.

10. Greater Focus on System-Level Testing

• Holistic Testing: As the complexity of avionics systems increases, there may be a shift toward more system-level testing rather than individual component testing. This could involve testing the entire avionics ecosystem for resilience, performance under various operational conditions, and how different systems interact with each other in challenging environments.

Is DO-160 Overseen by Any Key Standards and Guidelines?

Yes, DO-160 is overseen and developed by several key standards and guidelines that help ensure its alignment with broader safety, performance, and regulatory requirements in the aviation industry. These oversight bodies and standards organizations contribute to shaping and maintaining the DO-160 standard, ensuring it remains up-to-date and relevant for modern avionics systems. Here are some of the key entities and standards involved in the oversight and development of DO-160:

1. RTCA (Radio Technical Commission for Aeronautics)

• Primary Role: RTCA is the principal organization responsible for the development and maintenance of the DO-160 standard. It is a non-profit organization that provides a forum for the aviation industry to develop consensus on technical standards related to aviation.
• DO-160 and RTCA: RTCA provides the platform through which industry experts, including manufacturers, regulatory agencies, and testing laboratories, collaborate to develop the DO-160 guidelines. The standard is issued by RTCA as part of its broader mission to enhance the safety and reliability of avionics systems.
• RTCA and Other Standards: RTCA also oversees other critical aviation standards, such as DO-178C (software considerations in airborne systems) and DO-254 (hardware considerations in airborne systems). These standards, while separate from DO-160, are often complementary, especially in the context of integrated avionics systems.

2. FAA (Federal Aviation Administration)

• Regulatory Role: The FAA plays a significant role in the oversight of avionics standards in the United States, including DO-160. The FAA refers to DO-160 as part of the certification process for avionics equipment used in civil aviation.
• Certification Process: The FAA uses DO-160 as a guideline for testing and certifying avionics equipment. Any equipment that needs to be used in U.S.-registered aircraft must be tested according to DO-160 or a recognized equivalent to ensure that it meets the necessary environmental conditions and reliability standards.
• Collaboration with RTCA: The FAA works closely with RTCA in the development and adoption of DO-160 and other standards. The FAA also provides feedback and recommendations based on regulatory needs, operational experience, and safety concerns.

3. EASA (European Union Aviation Safety Agency)

• European Oversight: EASA is the European equivalent of the FAA and is responsible for regulating civil aviation within the European Union. Similar to the FAA, EASA recognizes DO-160 and incorporates its testing requirements as part of the certification process for avionics equipment used in European aircraft.
• Harmonization: EASA and the FAA work together through international agreements to harmonize their standards and certification processes. As a result, DO-160 is often referenced in both FAA and EASA certifications, ensuring consistency between U.S. and European aviation regulations.

4. ICAO (International Civil Aviation Organization)

• Global Regulatory Framework: ICAO is a specialized agency of the United Nations that sets international standards for civil aviation safety, security, efficiency, and environmental protection. While ICAO does not directly govern DO-160, its global standards provide a broader framework within which DO-160 operates.
• Alignment with ICAO: ICAO’s Annex 8 (Airworthiness of Aircraft) and Annex 10 (Aeronautical Telecommunications) provide global guidelines that influence the development of avionics systems, including the environmental testing standards covered in DO-160. These standards help ensure that avionics systems are consistent with international safety and operational requirements.

5. ASTM International (formerly American Society for Testing and Materials)

• Standards Development: ASTM International is an organization that develops and publishes voluntary consensus standards, including those related to aerospace technology. While ASTM does not directly oversee DO-160, certain ASTM standards are often complementary to DO-160, particularly in testing methods, materials, and processes.
• Aerospace Standards: Some aerospace-specific ASTM standards, such as those relating to materials testing, can provide additional context or clarification to the guidelines in DO-160, especially in terms of material properties and performance under environmental conditions.

6. MIL-STD (Military Standards)

• Military Requirements: The U.S. Department of Defense has its own set of standards for avionics and aerospace systems, including military versions of environmental testing standards. These standards, such as MIL-STD-810 (Environmental Testing) and MIL-STD-461 (Electromagnetic Interference), often align with or complement the testing criteria found in DO-160.
• Overlap with DO-160: While MIL-STD standards are primarily used for military systems, many of the test categories are similar to those in DO-160. In some cases, the two sets of standards may overlap, particularly in areas related to vibration, temperature, and shock testing.

7. Industry Groups and Certification Authorities

• AIA (Aerospace Industries Association): The AIA is an advocacy and standards organization that represents the aerospace industry. It works closely with regulatory bodies and provides input into the development of standards like DO-160.
• SAE International (Society of Automotive Engineers): The SAE is another technical standards organization that works on avionics and aerospace standards, including those related to avionics system testing and certification. Some SAE standards complement or are referenced in DO-160.

8. ISO (International Organization for Standardization)

• International Standards: While ISO standards are not specifically focused on avionics, some ISO standards are relevant to DO-160. For example, ISO 9001 (Quality Management Systems) and ISO/IEC 17025 (General requirements for the competence of testing and calibration laboratories) may apply to organizations that perform testing for DO-160 compliance.

9. Other Regional and National Regulatory Bodies

• CAAC (Civil Aviation Administration of China): China’s aviation regulatory body, the CAAC, also recognizes DO-160 and incorporates it into its certification process for avionics equipment used in Chinese-registered aircraft.
• Transport Canada: In Canada, Transport Canada Aviation applies DO-160 in its certification processes for avionics and other aircraft systems.
• Other National Authorities: Many other national aviation authorities (NAAs) incorporate DO-160 or a similar standard in their certification processes for avionics systems, ensuring that equipment is safe and reliable for use in their respective regions.

What Are Tips for Better Understanding DO-160

Understanding DO-160 can be complex due to the technical depth and the wide range of environmental conditions it covers. Here are some tips to help you gain a better understanding of DO-160, whether you are involved in avionics design, testing, certification, or regulatory compliance:

1. Start with the Basics: Know the Structure of DO-160

• Familiarize Yourself with the Sections: DO-160 is divided into 24 sections, each covering a specific environmental factor or testing requirement. Start by reviewing these sections to get an overview of the scope of the standard.
• Key Sections: Some sections to focus on early include:
  • Section 1: General Introduction (covers the purpose, scope, and applicability of the standard)
  • Section 2: Temperature and Humidity (important for testing the equipment in various climates)
  • Section 3: Altitude and Pressure (key for simulating flight conditions)
  • Section 5: Power Input (ensures avionics systems handle power variations)

2. Understand the Testing Procedures

• Test Types: DO-160 outlines various tests, including:
  • Environmental Tests: Testing for temperature, humidity, pressure, and altitude.
  • Mechanical Tests: Vibrations, shocks, and impacts.
  • Electromagnetic Tests: RF susceptibility, emissions, and electromagnetic interference (EMI).
• Test Levels: Pay attention to the levels of testing specified for each type of condition. The levels vary depending on the equipment’s intended use and environment (e.g., commercial aircraft, military aircraft, or general aviation).

3. Learn the Terminology

• DO-160 contains technical terminology that may be unfamiliar if you are new to avionics or environmental testing. Understanding terms like “Category A” (more stringent conditions), “Category B” (less severe conditions), and “Environmental Stress Screening” (ESS) is crucial.
• Glossary: Keep a glossary or dictionary of common testing terms handy. You’ll encounter terms related to power, temperature, vibrations, and frequencies that are critical for comprehension.

4. Work with Sample Test Reports

• Reviewing real-world test reports from previous DO-160 tests can help you understand how tests are conducted, how data is recorded, and how equipment failures or anomalies are addressed.
• Look for Example Equipment: If possible, find examples of avionics equipment that has passed DO-160 certification. Examine the test conditions and procedures that were used for certification.

5. Use Tools and Software for Simulations

• Many tools and software programs can simulate the environmental conditions specified in DO-160, such as thermal, vibration, and electromagnetic tests.
• Testing Software: Explore software used for environmental testing and simulation (e.g., LabVIEW, MATLAB, or specialized avionics testing software) to understand how these simulations are conducted.
• Digital Twin Technology: This allows you to virtually test equipment under various conditions, offering insights into how the equipment will perform in real-world situations.

6. Understand the Relationship with Other Standards

• Complementary Standards: DO-160 is not an isolated document. It often works in conjunction with other standards such as:
  • DO-178C: Software considerations in airborne systems.
  • DO-254: Hardware considerations in airborne systems.
  • MIL-STD-810: Military environmental testing standards (similar to DO-160).
• Knowing how DO-160 aligns with or complements these standards helps you better grasp the comprehensive requirements for avionics equipment.

7. Participate in Training and Workshops

• Many organizations and regulatory bodies offer training and workshops on DO-160. These training sessions provide practical insights into interpreting the standard and applying it to real-world avionics equipment.
• Certifying Bodies and RTCA: Some certification bodies, such as the FAA or EASA, may offer training courses on the implementation of DO-160. Additionally, RTCA may offer resources to help users better understand and apply DO-160.

8. Collaborate with Experts and Industry Peers

• Seek Expert Guidance: If you have specific questions or challenges in understanding the standard, it may be beneficial to consult with professionals who specialize in DO-160, such as certified testing labs, avionics engineers, or regulatory consultants.
• Industry Forums and Conferences: Participating in forums, webinars, and conferences focused on avionics or avionics certification can expose you to discussions on best practices, real-world experiences, and insights about DO-160 implementation.

9. Read Case Studies and Applications

• Case Studies: Look for case studies that describe how DO-160 testing was applied to specific avionics products. Case studies often highlight the testing challenges faced and how the standard was interpreted in real-world applications.
• Manufacturer Examples: Some avionics manufacturers or third-party testing labs provide detailed case studies or whitepapers showcasing how they implemented DO-160 for specific products. These documents help bridge the gap between theory and practice.

10. Review Regulatory and Certification Processes

• Certification Requirements: Understand the certification process that relies on DO-160, especially if you are involved in obtaining certification for avionics equipment. Familiarize yourself with how DO-160 fits into the broader regulatory framework set by bodies like the FAA, EASA, and ICAO.
• Audit and Compliance: Pay attention to the procedures for ensuring compliance with DO-160, including audit processes and how test results are documented and reviewed by regulatory bodies.

11. Stay Updated on Revisions and Changes

• Monitor Updates: DO-160 is periodically updated to reflect advancements in technology and the aviation industry. Make sure to stay informed about new revisions or drafts (e.g., the upcoming DO-160H) that may affect the testing requirements.
• Industry News: Subscribe to industry news sources, newsletters, and RTCA announcements to keep up-to-date with the latest developments in DO-160 standards and revisions.

12. Work with a Test Lab or Testing Facility

• Hands-On Experience: If possible, get hands-on experience by working directly with an accredited test laboratory that specializes in DO-160 testing. Observing how the tests are conducted, how results are interpreted, and how failures are handled will provide valuable insights into the practical application of the standard.

Ready to Learn More About DO-160?

Tonex offers several courses in DO-160, including:

DO-160G Training /  Environmental Conditions and Test Procedures for Airborne Equipment

EMI/EMC Test Procedures for Airborne Equipment Training Curriculum (DO-160G Training)

MIL-STD-461G & DO-160G Test Methods and Compliance Workshop 

Combo MIL-STD-461G & DO-160G Test Methods and Compliance Workshop

MIL-STD-461G / RTCA DO-160G EMC Test Methods And Compliance Training Essentials 

For more information, questions, comments, contact us.