Avionics Rack Mount Plates

Avionics Rack Mount Plates are engineered as critical structural-electrical interfaces for high-reliability aerospace environments. These plates provide a stable mechanical foundation that ensures precise positional repeatability and structural damping, essential for maintaining the integrity of sensitive avionics during variable flight conditions.

Material Specification

Aluminum 6061-T6 (AMS 4025), 7075-T7351 (AMS 4050), Stainless Steel 304L (AMS 5513)

Dimensional Tolerances

±0.05mm (Critical), ±0.1mm (Standard), Profile – ±0.2mm

Surface Finish

Ra ≤0.8µm (Mounting Faces), Ra ≤1.6µm (Non-Critical), Anodized (Class 2, 0.02-0.04mm)

Hole Specifications

Threaded (UNJF-3B), Clearance (H9), Counterbore Depth – ±0.05mm

Edge Deburring

≤0.1mm Radius (All Edges), No Visible Burrs (ASME B46.1)

Product Description

In addition to mechanical support, the plates offer conductive pathways that facilitate electromagnetic interference (EMI) containment and thermal transfer. This dual functionality enables the reliable operation of high-density electronic assemblies, ensuring consistent performance across a range of mission profiles and environmental stresses.

Chamfers/Counterbores

0.5mm x 45° (Standard), Counterbore Diameter – +0/-0.05mm

Flatness/Parallelism

0.05mm/m (Mounting Face), 0.1mm/m (Overall), Perpendicularity: 0.02mm

Post-Machining Finish

Alodine 1200 (Aluminum), Passivation (SS), Conductive Coatings (MIL-DTL-5541)

Marking

Laser Engraved (0.2mm Depth), Barcode (2D Data Matrix), Non-Flaking Ink (MIL-STD-130)

Inspection Requirements

100% CMM (ASME Y14.5), First Article (AS9102), Hardness Verification (ASTM E18)

Technical Advantages

System alignment errors between Line Replaceable Units (LRUs) and enclosure mounts can result in connector misalignment, intermittent contact, and fretting corrosion. The avionics rack mount plates are machined to sub-100-micron flatness tolerances and include datum-based alignment features that constrain all six degrees of freedom during insertion. These features reduce cumulative tolerance stack-up across modular chassis environments and ensure controlled interface engagement forces between edge connectors and backplane sockets. Mounting geometry is optimized to maintain mechanical decoupling from surrounding structural deflections during dynamic loading events.

Mounting transitions in avionics enclosures often become unintended leakage points for radiated and conducted emissions. To mitigate signal integrity degradation and crosstalk across mission-critical communication, navigation, and radar subsystems, Frigate avionics rack mount plates include fully integrated EMI gasketing channels, grounding tabs, and chassis tie points. Contact surfaces are engineered with defined impedance paths and conductive plating to provide consistent electrical bonding from module shield to enclosure ground. The interface system adheres to shielding effectiveness benchmarks as referenced in MIL-STD-461 and DO-160, ensuring compliance in high-interference operational theaters.

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Industry Applications

Flight Control Computers

Supports inertial navigation and control electronics with precise alignment, EMI shielding, and thermal conduction for real-time flight stability computation.

Mission Management Systems

Provides structural support and electromagnetic isolation for embedded processors managing sensor fusion, targeting logic, and tactical data link processing.

Communication Transceivers

Ensures proper grounding and mechanical stability for RF modules handling secure voice, SATCOM, and high-frequency data transmission in avionics bays.

Electronic Warfare Subsystems

Hosts high-density PCBs requiring vibration resistance and conductive enclosures for direction-finding, jamming, and signal processing in contested electromagnetic environments.

Flight Data Acquisition Units

Provides accurate mounting for data acquisition hardware capturing analog/digital flight parameters under thermal and vibrational stress during full mission profiles.

Load-Bearing Structural Continuity

Airborne electronics must endure multi-axis vibration, acoustic excitation, and transient inertial loads during flight and maneuvering. Structural instability at the mounting interface can result in fastener preload loss, connector disengagement, or PCB deformation. avionics rack mount plates are engineered from aerospace-grade aluminum alloys with controlled grain flow and stress-relief processing to avoid micro-yielding under cyclic loading.

Electronic subassemblies generate heat flux densities that exceed passive dissipation limits when improperly mounted. Avionics rack mount plates act as thermal spreaders, providing a conductive path from module heat sinks to system chassis or cold plates. Material selection, surface finish, and contact pressure uniformity are designed to optimize thermal contact resistance (TCR) and facilitate convective or conductive heat removal.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure minimal vibrational resonance in its avionics rack mount plates during airborne operation?

Frigate uses modal analysis during the design phase to predict and mitigate vibrational resonance across multiple axis modes. The mount plate’s geometry is optimized using FEA to shift natural frequencies away from critical system bandwidths. Damping materials or tuned isolators are optionally integrated based on payload sensitivity. This approach ensures stable signal integrity and mechanical reliability during extended flight hours.

What grounding methods does Frigate implement in its rack mount plates for EMI suppression in high-density avionics bays?

Frigate incorporates multi-point grounding schemes with conductive gaskets and precision-machined grounding tabs in each mount plate. All contact surfaces undergo chromate conversion coating to maintain conductivity and prevent oxidation. Shielding continuity is validated through milliohm testing across interface points. These measures suppress electromagnetic coupling and meet MIL-STD-461 compliance standards.

How does Frigate manage thermal expansion differentials between avionics enclosures and avionics rack mount plates in mixed-material systems?

Frigate selects alloys with matched coefficients of thermal expansion (CTE) when interfacing dissimilar components like aluminum enclosures with composite panels. Precision slotting and thermal isolation bushings are also used to decouple expansion movement. Structural integrity is verified through cyclic thermal shock testing between −55°C and +85°C. This prevents stress accumulation and misalignment during long-duration missions.

What machining tolerances does Frigate maintain for avionics rack mount plates to ensure seamless integration with quick-release brackets?

Frigate machines each mount plate to a flatness tolerance of ±0.05 mm and hole position accuracy within ±0.025 mm. CNC milling with adaptive feedback control ensures precision repeatability across production batches. Each part is CMM-verified against 3D CAD references before release. This guarantees tight interface fit with vibration isolation mounts and fastener systems.

How does Frigate validate structural performance of rack mount plates under asymmetric load conditions during emergency maneuvers?

Finite element simulations are conducted with off-center load distributions to mimic asymmetric g-forces encountered during evasive flight profiles. The mount plate is subjected to fixture testing at up to 9g dynamic loads along multiple axes. Strain gauge data is analyzed to ensure compliance with aerospace fatigue life requirements. These validation steps ensure plate deflection stays within acceptable limits under real-world conditions.

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