By Robert Pecaric Jr., President & CEO, Aerospace Devices Inc. | 2024 Aerospace & Defense Reviews USB Charging Company of the Year
Walk onto any modern flight deck, and you’ll count more USB cables than paper charts. Pilots power EFBs, dispatch tablets, backup radios, and personal devices from ports that didn’t exist a decade ago. But here’s what most passengers never see: those ports had to survive testing that would destroy consumer electronics in minutes.
At Aerospace Devices, we build aerospace testing and certification for the USB devices that pass those tests. Our SkyDock Pro series carries DO-160G qualification and OEM approvals from Bombardier, Embraer, and Dassault Falcon Jet. Here’s how that certification actually works, and why it matters when you’re navigating an approach at minimums.
What EFB Cockpit Power Actually Faces
An EFB Cockpit is not a friendly environment. Consumer chargers fail here for predictable reasons:
- Voltage swings: 28VDC nominal drops to 10V during engine start, spikes to 36V during alternator load dump
- Temperature extremes: -40°C cold soak to +105°C tarmac heat in operational profiles
- Vibration: Turbine and propeller frequencies that loosen connectors and fracture solder joints
- EMI: 400Hz power, weather radar, and communication transmitters create electrical noise
- Physical constraints: Confined avionics bays with limited cooling and crowded panel space
A Flight Deck USB-C charger must handle all of this simultaneously while negotiating power delivery with the connected device. No user intervention. No manual switching. Just stable output regardless of conditions.
The DO-160G Testing Breakdown
RTCA DO-160G defines twenty-six environmental categories. For aerospace testing and certification of USB devices, we test against the full profile relevant to permanent installation:
| Category | What It Test | Why It Matters |
| Temperature | -55°C to +70°C operational, survival to +85°C | Tarmac heat, altitude cold, thermal cycling |
| Altitude | Decompression to 70,000 feet equivalent | Unpressurized compartments, rapid descent |
| Vibration | Sine and random profiles per aircraft zone | Turbine/propeller frequencies, landing loads |
| Humidity | 95% RH at elevated temperature | Tropical operations, condensation in compartments |
| Salt Spray | Coastal atmospheric exposure | Corrosion resistance for maritime aviation |
| EMI Emission | RF radiation limits | Won’t interfere with VHF, GPS, or nav radios |
| EMI Susceptibility | Survival during intentional transmission | Keeps charging when the weather radar or TCAS operates |
We run pre-qualification testing at our Irvine facility before formal lab submission. This catches design issues early, when they’re schematic changes, instead of production disasters.
EMI Shielding: The Detail Consumer Makers Skip
Electromagnetic compatibility separates aviation hardware from consumer clones. Our approach:
- Controlled switching frequencies with proper filtering to limit conducted noise
- CNC-machined aluminum housings bonded to the airframe, ground for 60dB+ shielding attenuation
- Internal layout separation, keeping noisy power sections away from control circuitry
- Forced-PWM mode maintains consistent operation across load variations
The result? A Flight Deck USB-C charger that coexists with sensitive avionics rather than compromising them. This matters because EFBs are now primary flight instruments. Losing your chart display during an approach is a safety event, not an inconvenience.
Manufacturing Standards from an Aerospace Supplier in California
As an aerospace supplier in California, our AS9100 and ISO 9001:2015 certification means process control, not paperwork:
- Component traceability from receipt through installation
- Manufacturing records for every unit built
- Inspection checkpoints at critical process stages
- Qualification test reports accepted by major OEMs
Our Irvine facility handles design, prototyping, testing, and production under one roof. Custom bezels, mounting brackets, and faceplates come from the same engineering team that designed the core product. No specification drift or translation errors.
OEM approvals include:
- Bombardier / Lear Aircraft
- Embraer
- Dassault Falcon Jet
These relationships developed because we treated every installation as flight-critical infrastructure instead of a convenience feature.
Efficiency and Thermal Management
Waste heat in confined avionics compartments creates problems:
- Consumer chargers: ~65-70% efficient (30-35% becomes heat)
- Our SkyDock Pro series: 92-93% efficient at 100W output
That efficiency difference means:
- Less thermal load on surrounding avionics
- Smaller cooling requirements
- Longer component life
- Stable operation at temperature extremes
The aluminum housing isn’t just rugged; it’s a heat sink. CNC-machined from aerospace-grade alloy conducts thermal energy away from internal components while providing structural protection.
Voltage Flexibility That Actually Works
Our 12VDC TO 32VDC input USB-C charger configuration handles real aircraft electrical behavior:
- Nominal range: 12VDC to 32VDC covers standard 14V and 28V systems
- Survival range: 5VDC to 34VDC handles engine start sags and load dump spikes
- Automatic compensation: No manual switching, stable USB Power Delivery output
- Protection: Over-voltage, under-voltage, and reverse polarity safeguards
The pilot plugging in an EFB doesn’t know this is happening. The device just charges reliably through all phases of flight.
The TSO Path Beyond DO-160G
Environmental qualification is step one. For permanent installation, FAA TSO C71 adds:
- Manufacturing process control requirements
- Ongoing conformity verification
- Documentation accepted for installation approval
We’re actively pursuing TSO C71 authorization. For operators, this streamlines the approval path for hardware that already meets a recognized standard, reducing certification burden for individual aircraft modifications.
What “Aviation Electronics Manufacturer USA” Actually Means
The label gets used loosely. In our case, it specifies:
- Design and production in an AS9100-certified U.S. facility
- Direct engineering support for custom requirements
- Qualification documentation accepted by regulatory authorities
- Limited lifetime warranty reflecting hardware confidence
We’ve seen the aftermath of consumer-grade chargers in aircraft. The failures are consistent: thermal shutdown, EMI interference, connector fatigue, and voltage damage. Replacement costs exceed the certified hardware price difference many times over.
Where EFB Cockpit Charging Is Heading
Three developments shaping our roadmap:
Higher power density
- USB Power Delivery 3.1 expands to 240W capability
- More power in existing panel cutouts
- Critical as EFBs grow larger and more capable
Intelligent power management
- Chargers communicating with aircraft electrical systems
- Load reporting and remote monitoring integration
- Essential for electric aircraft and tight power budgets
Sustainability and modularity
- Replaceable port modules reducing e-waste
- EU PED compliance anticipation
- Efficiency metrics meeting expanding regulatory requirements
Built in Irvine, Proven in Flight
Every unit we ship carries the understanding that aviation doesn’t forgive shortcuts. When you specify Aerospace Devices hardware, you’re getting:
- DO-160G qualified designs
- OEM-approved manufacturing
- Direct engineering support from our California facility
- Documentation that simplifies your certification process
The validation that matters isn’t awards or press releases—though the 2024 Aerospace & Defense Reviews recognition confirmed our approach. It’s customers who specify our hardware after learning what uncertified alternatives cost them in reliability and safety.
Ready to specify certified cockpit power? Request technical specifications or contact our Irvine engineering team for integration support.
Frequently Asked Questions
Q: What testing standards apply to USB devices used in aircraft cockpits?
A: RTCA DO-160G covers twenty-six environmental and electromagnetic categories, including temperature, altitude, vibration, humidity, and EMI. For permanent installation, FAA TSO C71 adds manufacturing process requirements. Our hardware undergoes full DO-160G qualification with reports available for customer certification submissions.
Q: Why can’t I use a consumer USB-C charger for my EFB in the cockpit?
A: Consumer chargers lack voltage regulation, EMI shielding, temperature tolerance, and vibration resistance for aviation environments. They fail through thermal shutdown, electrical noise generation, or physical damage. The cost of an in-flight EFB failure, including potential approach interruption, far exceeds the certified hardware price difference.
Q: How does a California-based aerospace supplier support international customers?
A: Our Irvine facility provides direct engineering support, custom prototyping, and full AS9100-certified manufacturing. We ship globally to OEMs, completion centers, and MRO facilities. Documentation packages and qualification reports are managed from our U.S. base, ensuring consistent communication and traceability regardless of customer location.
Q: What input voltage range should a flight deck USB-C charger handle?
A: Aircraft electrical systems vary significantly during normal operations. A properly specified charger should handle at least 10V to 36V transients while maintaining a stable output. Our designs cover 12VDC to 32VDC nominal with survival to 5VDC-34VDC, ensuring reliable EFB charging through engine starting, alternator fluctuations, and ground power transitions.
