Spacecrafts must be able to withstand adverse conditions for many years.
The TESAT Parts Agency therefore supports you in the procurement of EEE parts taking various factors into account:
We identify the required EEE components based on your DCL: quality level, manufacturer, type, price, delivery time and the necessary testing and quality assurance measures depending on the mission. EEE components and their foreseen quality level are they key factors to succeed in reliability and cost performance.
A threat that increasingly affects the space industry are counterfeits. We inspect components in incoming goods inspection from the outside and in the DPA down to the die mask. In addition, wherever possible, only procure directly from manufacturer. All our suppliers are audited regularly.
There are many monopolistic suppliers for Hi-Rel EEE parts, which usually require close control of quality and schedule. We also build on second sources out of self-interest to prevent these dependencies. We do join forces with Airbus DS being a powerful buyer for our customers.
Many space EEE devices can be used not only for commercial but also military purposes. As a consequence multiple international export laws are in place. We ensure compliance with export control regulations. Our service covers the creation of EUS, the management of export licenses and the verification of the ECCN according to US and EU law.
Primes, agencies or even your customer needs CoC, lot traveler, DPA, TID and many other quality documents and reports. We ensure the completeness and correctness of such data. Therefore we will create a data package for each delivery, which you can also call up online in the future. We orientate ourselves to the well-known requirements of common primes and authorities for the respective missions. This will make it easier for you to approve your DCL / equipment and prepare you optimally for a customer review. We know from experience what you need and when you need it.
Typically, a huge convolute of different suppliers increase efforts and lead to a complex logistics. We consolidate your needs into one single point commodity and offer you various options like individual delivery, kitting or storage. We process and, if necessary, repackaging in such a way that the highest ESD requirements for the component are always guaranteed. Clean room handling up to ISO 5 / Class 100 is possible as an option.
Typically the delivery time directly influences EM, EQM and FM production. Therefore, we constantly monitor delivery times and act foresighted. Tesat has its own stock and stock parts shop where we are able to supply customers with Cass 1 equivalents. Further we organize time or in quality critical procurements in tight contact with our customers.
Sixteen specialized engineering & technology experts work on site at Backnang. Thanks to their experience from TESAT‘s own device manufacturing, they can reliably identify your requirements in order to offer specialized solutions for you.
This unique expertise of a component agency that “design & manufactures by itself” can be flexibly expanded. On customer request we have access to about 230 experts from the transnational Airbus EEE Centre. Our expertise is at your disposal!
The core discipline of the EEE engineering within TESAT is the search for components that guarantee a robust design and reliable processing technologies. They are the first steps on a long road to the final product. When selecting suitable components, it is not just about fulfilling all the requirements of the intended application, but at the same time having guaranteed availability at competitive price.
In our day-to-day business, we are the active partner of your development department and specifically – but not only – bring our weight into play when it comes to selecting components. We also have a market overview of the available EEE components and are experienced in the search for qualified alternative manufacturers. Of course, we also take responsibility for the technical and operational control of all required activities when unqualified components are required. This includes the various services such as construction analysis (CA), evaluation, (up-)screening, manufacturer qualification or radiation hardness assurance. We carry out almost all activities in our own laboratories. In this way, we can always consult the in-house manufacturing about the applicability of the results. In this way, we ensure that your results are not only theoretically applicable, but that your components are ready to use.
In our pool of 230 component experts we have specialists for every need. In several hundred Source Control Drawings (SCD) we have built up experience that is immediately available for you. Dealing with specification systems in Europe such as those of the ESCC family, the ECSS standards according to e.g. ECSS-Q-ST-60 for EEE Components or ECSS-Q-ST-30 derating is just as natural as with the regulations of NASA-STD-8739.10, the JPL and NASA Electronics Parts & Packaging (NEPP) guidelines such as the EEE-INST-002, or the JAXA Japanese system such as the JAXA-QTS detail specifications.
We look forward to your contact, you will benefit from our unique experience in accompanying product developments through our knowledge about volume production. We support you in the selection of new components or components with different quality requirements and can offer you tailor-made solutions according to your needs.
Parts Agency can carry out almost all Failure Analyses (FA) in its own laboratories. Across the group, we have additional special laboratories at the respective Airbus locations available upon your request. Sixteen experienced technologists specialized in the respective component family take over the planning and implementation of the FA. As a result, you will receive a report that, in addition to the cause of the failure, also gives recommendations for avoiding further.
Product managers for electronics know that immense costs are involved in the development and qualification of new boards. Nevertheless, even with components, a failure can creep in anytime and anywhere and thus raise big questions. In order not to jeopardize the investment, it is important to know the possible root causes of failures very quickly and determine counter measure.
Our state-of-the-art analysis laboratory and our methods offer well-founded possibilities to quickly narrow down the cause of the error and determine it as precisely as possible. The technologists are experienced employees who also carry out failure analyses for TESAT’s own equipment. We apply the same, highest quality standards to both analyses.
Our analysis methods and laboratory equipment conform to all common space systems - but also to those of industries beyond. The procedures under a FA are largely similar to those of a DPA. Due to the specialization of our laboratories on EEE HiRel devices, there is almost no limitation in the research method. In the first step, the errors are verified, for example by electrical tests with a SZ system, leak test or visual control (EVI) according to MIL-STD-750 or ESCC 20500. Various imaging methods, such as the C-SAM, support X-Ray as the most times chosen initial assessment. Further processes are used in the course of the research into the causes. With the penetrant dye test as a special variant of the Hermetic Seal Test (MIl-STD-750, Method 1071, Cond. E), even the smallest leaks can be identified and localized by fluorescence under UV light.
With the experience of the component laboratory, a number of unconventional possibilities have emerged as to how components can be opened without being destroyed. This almost craftsmanship is also a quality feature on this minimized level of component treatment, which cannot be told by any specification. We always keep an eye on market developments. Therefore, we are trained in opening plastic components with and without jet etcher. Even opening with a laser is not a problem for our technologists. After opening the component, further analyses can then be carried out to meet the requirements of ESCC 20400 or MIL-STD-750 and MIL-STD-883. The often visible damage is mapped using an optical microscope down to 1 µm or SEM down to 0.1 µm. The possibility of performing a material analysis or mapping (element mapping) in the SEM even makes melted whiskers visible.
Contact us for a failure analysis (FA) and benefit from the experience of our technologists. Our EEE laboratories are certified according to EN / AS 9100. This standard guarantees a quality management system that meets the high demands of aerospace and the defence industry. Our in-house calibration laboratory is also ISO 17025 accredited.
If components are used for the first time in space industry, it is essential to assess structure and construction in detail. In particular, weak spots in semiconductor and assembly must be made visible. Our experts carry out the analyses and, in a final statement, evaluate the risk for use in your space-specific projects.
We use the process of construction analysis for almost all of our components in introduction phase. It is important to determine as completely as possible all the information that is not visible from the outside, but even more valuable for assessing the reliability of the application. The typical steps of a construction analysis (CA) begin with an assessment of how an application-related condition of the components can be achieved, e.g. if the components are to be pre-tinned in later use. Such process must also be assessed and therefore included in the CA to match the later in-build conditions. As an example, a typical test procedure can look like this:
External Visual Inspection (EVI)
X-Ray (Radiographic Inspection)
Lead finish analysis before retinning
Lead finish analysis after retinning
Terminal strength test
Opening procedure/ moulding removal
Internal Visual Inspection (IVI)
Bond wire pull test
Bond shear test
Internal Visual Inspection (IVI)
During the C-SAM according to ESCC22500,JEDEC-STD-020 and JEDEC-STD-035, the first critical points of plastic encapsulated components can be identified. In the further course, the workmanship will be examined in more detail with further tests such as X-Ray and IVI. The experience of the Parts Agency plays a special role here. Thanks to more than 50 years of expertise in component approval and failure analysis, we have built up an enormous experience, which means that material combinations and assembly technologies can be assessed with nearly no compromise. The assessment of assembly technology can often be made using bond wire pull tests according to MIL-STD-883. Here, reference is also made to the thickness of wires, the material, their type of bonding and the possibilities for improvement in manufacturing process. A special service comes to the fore: we offer the opportunity to share our experience with the manufacturers so that optimizations can be introduced in the the production process for your customized device. In specific cases, we also work with the manufacturer to eliminate structural defects in components for your application.
In summary, our analysis methods and machines allow us to examine the majority of all EEE components for the technologies and materials used and to validate the suitability for certain space applications.
We would be happy to accompany you during the introduction phase of your new components: help you to draw up the test plan, performthe analyses and complete with the evaluation of the results. With our processes, we ensure that all stakeholders and interest groups can approve the selected component. Contact us and benefit from our know-how, we would be happy to tailor and adapt for you to pave the way for your success.
Printed Circuit Boards
TESAT owns several production and assembly lines for printed circuit boards of various materials, including ENIPIG surface. Our lines are ESA qualified and therefore offer full space suitability. In combination with the procurement of components, we offer the assembly of printed circuit boards in one package. Kitting & Storage services for JIT deliveries are also available.
TESAT is the first manufacturer of printed circuit boards, which besides lead-tin printed circuit boards can also offer ESA certified printed circuit boards with the multi-functional surface ENIPIG (Electroless Nickel Immersion Palladium Immersion Gold). In addition to soldering (PbSn & SAC) EEE components, the new ENIPIG surface also enables direct electrically conductive gluing and gold wire bonding.
Currently, the ESA certificate includes µvia technology (connection of layer 1-2 and layer 1-3) – here too, that makes TESAT the European technology leader in space industry! From standard products to complex structures,we manufacture state-of-the-art printed circuit boards for you for almost every application.
ESA certified manufacturing of PCB (ECSS-Q-ST-70-60C)
IPC 6012 (rigid printed boards)
IPC 6016 (high density interconnect layers or boards)
IPC 6013 (flexible printed boards)
All PCBs needed for production by TESAT are manufactured in-house, and this service is provided to you 1:1. You willreceive products with the highest standards. You can rely on 100% qualified circuit board technologies that have a unique heritage in a large number of satellite projects. The product range includes double-sided, multilayer, flexible and composite circuit boards as well as special designs with an integrated metal / ceramic core for controlled thermomechanical expansion and heat conduction. Basically, High-Tg-FR4 is used as the base material. Summing up, the two ESA qualified lead / tin end surfaces (also possible in combination with a copper / tin diffusion layer for screwing / fastening) and ENIPIG are available from TESAT.
We offer you customized E2E services thanks to our own production lines: from EEE and mechanical components, to printed circuit boards, assembly and kitting to device manufacturing – all of that fit for space applications!
We process our service packages with the background of our long history of own manufacturing experience, for you to gain the optimum benefit from it. Furthermore, we are happy tosupport you on the qualification of components or to provide our technical advice on further production steps in your own production.
TESAT has always been the manufacturing company with the worldwide only series production for laser communication terminals, RF devices and EPCs for space application. We will share our Know-How for your benefit as our capacities in the combination of different production areas are particularly interesting for EEE components:
(thermal) wafer probing
hybrid manufacturing according to ESCC 2566000
PCB production according to ECSS-Q-ST-70-60C and IPC 60xx
HiRel storage and nitrogen storage
Even if you only need advice or assistance in partial areas you always benefit from the experience of our experts for all up- and downstream stages of the value chain. We are used to look beyond the core task in order to deliver ready-to-use products. Thanks to our partly highly automated series production on 12,000m² cleanroom, we can realize high volume while maintaining high quality. To do so, we thrive for automation such as our mainly used SZ systems in the incoming goods inspection or screening with simultaneous monitoring for electrical tests. Our production lines are qualified according to ESCC, and we are a certified known shipper for military and space application.
OurOur very experienced project managers accompany your component process in all project phases and are the focal point for your questions. All functions of component procurement, engineering, quality, laboratories and manufacturing are combined at the site in Backnang. As a result, we are closely networked with direct exchange of all functions involved in projects. We guarantee short decision-making processes and fast communication.
At the site in Backnang, the two partner departments Parts Agency and EEE Centre merge with TESAT Manufacturing. The short decision-making and communication channels make the Parts Agency a one-stop-shop for EEE components and a borad portfolio of services for COTS and HiRel space parts. Your first point of contact are ten experienced project managers and four quote coordinators. They take over the coordination of your procurement projects, from quote to order acceptance, to procurement and production to further services after delivery or completion of the project.
Another focus is on the particularly critical schedules in the space market. On the one hand, the start date of launches represents an almost unchangeable finish date for manufacturing and test. On the other hand, the manufacturing of EEE components for space is extremely demanding, which is why close coordination with the manufacturers is required. At this interface, we see the greatest advantage to bring our expertise to you as our customer. For your EEE procurement- and service projects we are using our long-lasting experience and well-established processes as space equipment manufacturer with an output of more than 1.000 units per year.
For our employees we guarantee a very high level of quality through regular training and audits. Common management certifications such as PMI or Six Sigma are part of our philosophy. Furthermore, our project managers are audited according to the Airbus standards for project and program management skills.
The aim of our services is always to support you in making decisions and to unburden you as much as possible from coordination tasks. Therefore, we create a PAD for each component naturally, take care of the necessary export regulations if necessary and include all procured components in our NCR / Alert Management System. In order to reduce the administrative hurdles in everyday business there is the possibility of a SAP interface to connect the ERP systems of yours and TESAT, order in one click. In addition we offer our customers our internet reporting suite, operating with any browser and platform, allowing in daily updates to control the status of your project.
We are very happy that we receive constant customer awards about our performance. We believe that your feedback is the best and only one that gives us proof our service.
Radiation effects do affect every component in space as it will increasingly affect also sensitive applications like autonomous systems in the near futute. We analyze the critical parameters of your components and design a test plan to test weak and strengths for your desired application. Taking into account the test specification, our radiation specialists ensure that the tests run smoothlywith their hands on. After completion, the results will be assessed and options are shown.
Radiation is generally an exciting challenge that every participant in space industry – regardless of classic or NewSpace – has to face. Thematically, a colorful bouquet full of processes, terms and technologies opens up behind the term of radiation. This special knowledge is owned by special teams of experts. Since we also carry out radiation analyses for our own devices from LEO and MEO to geostationary orbits (GEO), we can determine the optimal test procedure based on your mission parameters. In the NewSpace area in particular, we can carry out a rough estimate in advance based on our experience and models. Thus, the effort for test campaigns can be significantly reduced.
On site at Backnang, we have ten engineers who deal exclusively with radiation. This is necessary as we conduct about 60 to 70 radiation tests per year. We cover all subject areas, from Single Event Effect (SEE) tests with heavy ions and protons at different angles of incidence to classic Co60 Total Ionizing Dose (TID) tests in enhanced low dose rate (ELDRS) or high and low dose rate (HDRS / LDRS) and Displacement Damage Dose (DDD) tests.
Special technologies are required to prepare plastic EEE components for testing for single event latch-up (SEL), single event transients (SET) or even single event gate rapture (SEG) and burnout (SEB). Examples are the highly sophisticated opening of standard plastic housings with functioning components up to highly integrated 3D structures like that of an ADUM digital isolator.
Contact us and benefit from our experience in all relevant radiation issues. We can offer you prompt support and adapt work packages to your needs. Regardless of whether you need support in determining radiation load in the mission, the correlation of technology and radiation resistance or already in determining the relevant standards for your products. We speak all languages and comply with ECSS-Q-ST-60-15C and ESCC-22900 / ESCC-25100 as well as the classic US regulations such as MIL-STD-883 and MIL-STD-750.
You want to learn more about radiation? Lets get in touch as we are preparing a 2-day radiation training in the frame of your Tesat Campus network. You will learn about topics like Basics & Effects in different Orbits, RHA Effects per device, Testing & Analyze or even OMEA/WCA/FMECA. Lets get in touch: firstname.lastname@example.org
X-Ray / C-SAM
X-Ray / C-SAM
X-Ray analyses allow a quick look into the component without destroying it. The more simple imaging method is often sufficient for an initial analysis. For plastic components (COTS), another non-destructive test is commonly used to look for their specific defects: scanning acoustic microscopy (SAM or C-SAM). Plastic components require C-SAM within the evaluation / LAT and possibly the screening in order to justify use in space properly.
The X-Ray inspection according to MIL-STD-883 is a non-destructive test and offers very good options for assessing the quality of EEE components within DPA, for failure analysis or as an additional screening step. For example, one checks the lid soldering, the die attach on voids, the offset of components, bond lifters or just the workmanship. This well established non-destructive test can also be used for COTS components, but the most commonly non-destructive test used for COTS is SAM because of their specific defects. The focus here is mainly on molding defects like voids or delaminations that are not visible using X-Ray. With scanning acoustic microscopy (SAM) sometimes also referred as acoustic micro imaging (AMI), a horizontal acoustic sectional image of components is created in the so-called C-mode (C-SAM). This can be used to identify critical molding defects or to assess package degradation during an Up-Screening or LAT. Common specification used for SAM are JEDEC standards J-STD-020 and J-STD-035 or ESA standard ESCC 25200. Although C-SAM is a young technology in space industry, we already have an excellent background, especially with COTS and automotive parts. With an average of ten analyses per month, C-SAM has become standard, while only being exceeded by X-Ray examinations of around 50 per month.
Both investigations are essential for assessing the quality of components and therefore play an overriding role in daily routine. Our new PVA SAM 301 system is capable of recording high-resolution acoustic images (echo and dynamic through scan). Further, it expands our existing excellent non-destructive analysis capability (real time X-ray and CT). Contact us and benefit from our technology and experience. We look forward to your requirements and the opportunity to support you.
By the way: TESAT is a competence center for the opening of plastic encapsulated microcircuits (PEMs) and has developed a knowledge advantage from which you can benefit by combining different opening technologies such as with the (Laser) Jet Etcher.
Are you looking for an EEE component that fits your design perfectly but manufacturer refuses to guarantee its use in space? Based on that challenge, we will work out a milestone concept for Up-Screening with our more than 50 experts in engineering, testing and procurement. As we can carry out almost all steps of an Up-Screening ourselves, we can offer maximum transparency and control. In this way, the efficiency at the cost and quality level is kept consistently high.
Up-Screening of EEE components refers to the implementation of a precisely specified testing flow or test sequence, which allows the use of electronically safe components of lower quality levels (COTS, industrial or automotive grade) in projects with high quality requirements. Space or rocket applications are a typical target. In this area in particular, growing price pressure,the implementation of new electronic functionality and the obsolescence of space-qualified components forces users to break new ground. Up-Screening according to common standards (e.g. ECSS-Q-ST-60-13, MIL-STD-883 TM 5004 and 5005, MIL-PRF-38535/38534, MIL-PRF-19500, etc. ...) or customer-specific requirements can be the way forward. This applies to discrete components such as MOSFETs, bipolar transistors (BPT) or diodes as well as to complex integrated components (ICs, ASICs, multi-chip modules (MCM), hybrids or customized microelectronic solutions). In addition, inexpensive and readily available passive components such as capacitors, resistors and inductors are particularly suitable for Up-Screening. The steps to make a component “fit for space” are not standard, but the following general points are usually taken into account:
Process steps (exemplary)
Definition of functionality, obsolete or high-priced HiRel components that are to be replaced by up-screened alternatives.
TESAT proposes COTS, industrial- or automotive-grade components and corresponding Up-Screening test plans that are suitable for achieving the goals defined in (1).
Procurement of components and preparation of test campaign, drawing up a project schedule.
Execution of the tests. After the test campaign has been completed, the components are delivered with a test report and CoC and/or JD (justification document).
TESAT solution and expertise
With a team of more than 50 component specialists in the areas of engineering, testing and procurement, TESAT delivers the perfect solution for your Up-Screening needs. You can either tell us which components you want to up-screen or we will find suitable candidates based on your requirements. From the procurement of components to the development of test plans and the implementation of the individual tests: TESAT offers you to commission the entire process in-house from a single partner. By the way: Our 200 m² EEE laboratory is certified by TESAT according to EN / AS 9100. This standard guarantees a quality management system that meets the high demands of aerospace and the defense industry. Our in-house calibration laboratory is accredited according to ISO 17025.
The process from inquiry to delivery
The starting point of your request are quantities and part designations. You can help us by also providing at least the columns from our inquiry form. In general, Excel queries are the quickest to process. We convert your part designation to the manufacturer and specification ones and clarify important details such as additional tests, alerts and delivery times.
Based on your project requirements, we check your DCL and identify the EEE components or alternatives you need: quality level, manufacturer, type, price, delivery time. Depending on your mission, we recommend the necessary additional test and quality assurance measures. We also take current delivery problems and manufacturing peculiarities into account. In the event of special requirements or low availability, we offer alternatives through up-screenings or own stock base.
With our quote we typically provide you several options to choose from. Stock parts are specially marked as they are non-reserve parts. We always compare your request with our offer, so that you can immediately identify alternatives for you.
In the often monopolistic procurement market for EEE components, we also rely on second sources out of our own interest to prevent dependencies. Regular audits are carried out together with Airbus DS, SAP helps with permanent delivery tracking. In the Tesat Parts Agency EEE reporting portal you can always check the up to date delivery dates. We create technical documents (e.g. PAD) for you as additional quality assurance in procurement, this service is for free.
Quality and the highest standards are also set in the delivery. We are a MIL-certified, safe shipper and send out with all major freight companies as required. We perform customs declarations so that the delivery can reach your destination as quickly as possible. Choose your option if devices are packed in one single package or already kitted ready to use for manufacturing.
We also accompany you after the final delivery. Support in PCB meetings with your customers, NCR management, error analysis, PCN and warning notes as well as obsolescence management are part of our full package services. Further we store your components, and prepare them for individual orders or call-offs. Our long term storage keeps documentation for more than 10 years and ready to pick at every time.
e pioneer with passion and strive to be the number one partner for your success. We provide solutions to meet all you EEE component and PCB needs. We are in direct personal contact with our customers and suppliers and will work trustfully and performance-oriented with them together. We are looking forward to work together with you!
The new product from the TESAT Parts Agency, the TESAT Campus, is your first address for professional training in space industry. Conducted by TESAT experts from engineering and quality, this training offers the opportunity to get to know the challenges of the component market.
In order for you to be able to use the knowledge imparted for your task area, the training focuses on the problems of procurement and the opportunities and risks of the future. In addition, the “New Space” market is examined and the growing demand is addressed. Experience and know-how are conveyed and shown how all important aspects relating to performance, quality and reliability can be guaranteed in various projects.
Along the entire process from component to finished project, TESAT Campus offers opportunities to make your working day easier. A deeper understanding of the work of our experts can help to bring your projects to a more effective conclusion.
Perform a Destructive Physical Analysis independently with the support of our experts.
In the three-day training with an optional fourth “Lab Day”, you will learn about the challenges and solutions for conventional and New space business.
Get to know the difficulties of procuring components. Our experts are at your disposal at any time.
Dear Readers of the TESAT Parts Agency Newsletter,
after an excellent start into 2020, we all were suddenly hit by an exceptional situation: COVID-19. At the TESAT Parts Agency, the planning of custo...