RTCA DO-160 - The ideal support from Weiss Technik
Factsheet
RTCA DO-160
Test requirements for electrical and electronic equipment in aerospace systems
RTCA DO-160
RTCA DO-160 is a key test standard for environmental and electromagnetic compatibility (EMC) testing. It was developed by the Radio Technical Commission for Aeronautics (RTCA) in order to ensure that aviation equipment operates reliably under the typical and extreme conditions of flight operations. The standard comprises a range of test procedures for factors such as temperature, altitude, vibration, humidity, lightning strike, and electromagnetic interference. Under DO-160, devices are classified into categories that vary depending on the installation location in the aircraft and the operational profile. This ensures that the tests are practical and tailored to the specific use case. Many DO-160 test procedures can be carried out using testing equipment from weisstechnik.
For each test item, we offer the right solution: from compact bench-top models with a 16-liter test chamber volume to reach-in test chambers to drive-in systems for large-volume test items. In addition to our standard products, we work closely with our customers to develop customized solutions precisely tailored to their specific requirements.
Nice to know: RTCA DO-160 is recognized worldwide by aviation authorities such as the CAA, FAA, EASA, and Transport Canada. Proof of conformity is often a prerequisite for the certification of aircraft and the issuance of airworthiness certificates.
RTCA DO-160 is used to ensure the reliability of airborne equipment under environmental conditions. Using high-precision testing technology, Weiss Technik GmbH supports companies in the standards-compliant development and qualification of their products.
Civil/commercial aviation
Manufacturers of avionics, onboard electronics, and cabin systems must comply with DO-160 because this forms the basis for certification in commercial aircraft.
Typical test items: flight management systems (FMS), cockpit displays (PFD, MFD), transponders, ADS-B devices, cabin lighting, PSU modules, and in-flight entertainment (IFE) systems.
Military Aviation
Also military aircraft frequently use RTCA DO-160, particularly when commercial-off-the-shelf (COTS) components from the civil market are adapted.
Typical test items: navigation equipment and mission computers, communication systems (e.g., UHF/VHF radios), and military UAV electronics (e.g., electronics bays, power supply units).
Urban Air Mobility and eVTOL Industry
Manufacturers of electric air taxis and drones for passenger transport or delivery purposes follow DO-160 in order to demonstrate electromagnetic compatibility, vibration resistance, and battery safety.
Typical test items: eVTOL flight control computers, battery management systems (BMS) for aircraft, high-voltage inverters, and electric motor control units
Unmanned aircraft systems (UAVs/professional drones)
Professional drones used for inspections, surveying, or government missions are increasingly aligned with DO-160 in order to ensure reliability and airspace approval.
Typical test items: autopilots for UAVs (e.g., Pixhawk-based aviation variants), GNSS receivers for UAVs, and telemetry and radio modules
Satellite and Space Industry
Although there are specific spaceflight standards (NASA, ESA), DO-160 is used for components deployed in both aviation and space applications or when previous testing according to DO-160 is already considered valid.
Typical test items: electronic subsystems for small satellites (CubeSats), power supply modules, and communication transceivers
Helicopter Industry
Helicopters generate extreme vibrations and temperature fluctuations. DO-160 is therefore a standard requirement for all electronic systems used.
Typical test items: helicopter avionics, rotor monitoring systems, GPS trackers, and emergency locater transmitters (ELTs)
Temperature and Altitude
In aviation operations, electronic systems, materials, and enclosures are exposed to a wide range of environmental stresses, particularly at high altitudes and during rapid climb and descent phases. In such scenarios, low ambient temperatures, reduced air density, and abrupt pressure changes act on the components. These conditions can affect thermal expansion, electrical insulation, mechanical stability, and condensation behavior, thereby endangering the functionality and structural integrity of the devices.
RTCA DO-160G Section 4 defines a wide range of test procedures for temperature and altitude stresses. Depending on the installation location, maximum operating altitude, and pressure conditions, specific tests are used to simulate realistic operating environments.
These include:
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Temperature tests simulating extreme cold and heat exposure
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Pressure tests simulating reduced ambient pressure at high altitude
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Decompression tests simulating sudden cabin pressure loss
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Overpressure tests simulating elevated cabin pressure
These tests enable early identification of potential weaknesses such as seal failure, condensation, embrittlement, and thermal stresses. They are essential for the development of reliable aviation equipment that must operate safely even under extreme environmental conditions.
Section 4.5.1: Low-temperature test at the low ground survival temperature and short-term operation at low temperature
Section 4.5.2: Low-temperature test for operation at low temperature
Section 4.5.3: High-temperature test at the high ground survival temperature and short-term operation at high temperature
Section 4.5.4: High-temperature test for operation at high temperature
Section 4.5.5: High-temperature test for in-flight cooling failure
Section 4.6.1: Altitude Test – Operation at reduced ambient pressure
Section 4.6.2: Decompression Test
Section 4.6.3: Overpressure Test
Temperature fluctuation
Aviation devices are often exposed to abrupt and repeated temperature changes (e.g., during rapid altitude changes, transitions between air-conditioned and non-air-conditioned areas, or installation in external locations). The temperature fluctuation test according to RTCA DO-160G Section 5 simulates these real-world stress scenarios through cyclic testing between defined operating limits.
The objective is to evaluate the effects of thermal stress on materials, enclosures, electronic components, and interfaces. The focus is on thermally induced stresses, material fatigue, crack formation, condensation, and functional deviations. Rapid temperature gradients are particularly critical because external and internal components heat up or cool down at different rates.
Section 5: Temperature fluctuation
Humidity
In aviation, electronic systems and materials are frequently exposed to humid environments, whether because of natural climatic conditions, condensation during temperature fluctuations, or operational influences such as air circulation in non-air-conditioned areas. The humidity test according to RTCA DO-160G Section 6 is used to assess whether devices are resistant to corrosive, electrical, chemical, and thermal effects resulting from moisture absorption.
Typical risks are:
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Corrosion of metallic components,
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Leakage currents and insulation failure in electrical components
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Chemical reactions of hygroscopic materials
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Thermal changes in insulators and enclosures
Section 6: Humidity Test
Explosion Safety
In certain aircraft areas (e.g., near tanks, lines, or ventilation systems), flammable gases or vapors may be present. The test according to RTCA DO-160G Section 9 is used to assess the safety of devices operated in such zones in order to ensure that, under normal operating and fault conditions, they do not constitute an ignition source.
The test procedures include:
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Non-ignition test: Verification that the device does not cause ignition.
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Containment test: Evaluation of whether an internal ignition remains contained within the device.
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Surface temperature test: Assurance that no component heats up beyond 204°C.
Devices classified into three categories:
Category A – Hermetically sealed or explosion-proof.
Category E – Not hermetically sealed but ignition-protected.
Category H – Devices with hot surfaces, but without spark formation.
Section 9: Explosive Atmosphere Test
Protection against water
Aviation equipment may come into contact with water during operation (e.g., through condensation, dripping water, spray mist, or jet water during de-icing). The waterproofness test according to RTCA DO-160G Section 10 evaluates the sealing integrity and functional performance of devices under such conditions.
The objective is to ensure that water exposure does not result in malfunctions, corrosion, or leakage.
The tests are conducted according to the equipment category:
Category Y – Condensation water: Temperature fluctuations between cold and humid environments.
Category W – Dripping water: Simulation of water dripping vertically onto the equipment.
Category R – Spray water: Spraying from multiple directions.
Category S – Jet water: High-pressure water jets (e.g., during de-icing).
Section 10: Waterproofness Test
Sand and dust
Fine particles such as sand and dust can cause severe damage in aviation applications, particularly to devices installed in unprotected or ventilated areas. The DO-160 tests simulate real-world stress scenarios involving airborne dust or sand that may occur during normal flight operations. The objective is to assess the resistance of devices to the ingress and accumulation of particles. Critical effects include contamination and blockage of moving parts, relays, or filters, the formation of electrically conductive bridges, the promotion of corrosion because of moisture and condensation nuclei, the impairment of seals and bearing points, and the contamination of operating fluids.
The tests are conducted according to the device category:
Category D – Dust exposure: Testing with fine particles under moderate airflow.
Category S – Sand and dust exposure: Testing with coarse particles and high wind velocity.
Section 12: Sand and Dust Test
Salt spray mist
Salt-containing atmospheres such as those near coastal areas or at airfields where de-icing operations are used place a high level of stress on electronic and mechanical systems. The DO-160 salt spray test simulates these real-world conditions in order to evaluate the susceptibility of materials, coatings, and sealing systems to corrosion. The objective is to analyze the effects of long-term salt exposure on the functionality and structural integrity of devices. Typical risks include corrosion of metallic surfaces, contacts, and enclosures, blockage of moving parts caused by salt deposits, insulation failures caused by conductive residues, or contact problems in unprotected cables and connectors.
The tests are conducted according to the device category:
Category S – Standard salt mist exposure: Alternating salt mist exposure and drying over two cycles.
Category T – Severe salt mist exposure: More intensive exposure followed by functional testing and insulation resistance measurement.
Section 14: Salt Mist Test
Protection against icing
Devices installed on the exterior of the aircraft or in non-air-conditioned areas may be exposed to icing under real flight conditions (e.g., as a result of rapid changes in temperature, altitude, and humidity). The icing test according to RTCA DO-160G Section 24 evaluates the effects of ice formation on the mechanical function, electrical performance, and structural integrity of aviation equipment.
The objective is to ensure operational capability under icing conditions or validate the effectiveness of de-icing.
The tests consider various forms of ice formation:
Category A – Frost and condensation icing: Evaluation of functional performance under frost formation caused by temperature fluctuation.
Category B – Mechanically critical ice formation: Testing of moving parts under conditions of condensation, melting, and refreezing.
Category C – Ice accumulation from water: Simulation of ice buildup on cold surfaces and evaluation of the maximum tolerable ice thickness.
The tests are conducted under alternating climatic conditions, preferably using separate climate chambers.
Section 24: Icing Test
factsheet with measured data