Modern military avionics power supplies a DFM challenge

A complex military, avionic power supply was designed for the F-22 aircraft, supplying 5 independent outputs for critical aircraft systems. It was designed in a short schedule, was required to operate in extreme environments for an extended life, be lightweight, and be packaged in a standard single wide SEM-E format. Although difficult in itself, the real challenge was to design the assembly in a producible way, keeping Design for Manufacture (DFM) as a critical factor. Many factors, administrative to technical, combined to achieve DFM goals for this power supply. Teaming arrangements, program planning, computer modeling, circuit partitioning, three dimensional packaging, printed wiring board design, materials selections, component selections, including lead forms all contributed to a design that met all performance requirements as well as cost goals. The results was a product that will serve our country well into the 21^st century on America´s air superiority fighter