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Aerospace & Defense PCB Manufacturing and Assembly

Sierra Circuits manufactures and assembles extremely reliable IPC 6012 class 3/ES PCBs in as fast as 2 days. Rugged, reliable boards, rigorously tested and fully documented.

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Product image 1: Aerospace & Defense PCBs

An experienced mil-spec PCB manufacturer for aerospace and defense

Sierra Circuits is proud to serve those who serve. That’s why every mil-spec PCB we manufacture receives priority scheduling for fast-track production.

  • Next day for standard FR-4 or double-sided PCBs
  • 2–4 days for 4-layer to 8-layer PCBs
  • 5 days for 10-layer PCBs and above
  • 5–10 days for HDI, rigid-flex, flex, and metal core PCBs

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Product Promise

Sierra Circuits is an aerospace and defense PCB manufacturer that provides full intellectual property protection. All mil-spec boards are ITAR certified.

Documentation we provide:

  • Certificate of conformance
  • Material specifications
  • Reflow profile copy (included with first article)
  • Photo requirements
  • First article inspection report
  • IPC J-STD-001E
  • Record of calibrated tools used during manufacturing
  • AOI report or visual inspection report
  • Flying probe or in-circuit testing report
  • Ionic cleanliness test report

If you don’t see the documentation or testing required for your project, contact us—and you’ll find expert insights on how we’ll perform the test you need.

For the best mil-spec boards, stick to the following parameters:

  • The dielectric thickness between two planes: 3.5 mil minimum
  • Annular ring for inner layer: 6 to 7 mil minimum
  • Annular ring for outer layer: 6 to 7 mil minimum
  • Drill to copper clearance: 7 to 8 mil
  • Tolerance of 1 to 2%

Note: These parameters are not mandatory but if followed your boards will be manufactured close to perfection.

Sierra Circuits' capabilities for aerospace and defense PCBs

Product Features Rigid PCBs HDI PCBs Rigid-flex PCBs
Max Layer Count 30 24 +\- 16
Min Board Thickness .01″ (.254 mm) .01″ (.254 mm)
Max Board Thickness .25″ (6.35 mm) .25″ (6.35 mm)
Min Core Thickness .002″ (.051 mm) .002″ (.051 mm) .001″ (.025 mm)
Min Dielectric Thickness .002″ (.051 mm) .002″ (.051 mm) .001″ (.025 mm)
Min Starting Copper Foil Thickness/Weight 9 micron (0.25 oz) (.009 mm (7.4 ml)) 9 microns (0.25 oz) (.009 mm (7.4 ml)) 9 microns (0.25 oz) (.009 mm (7.4 ml))
Max Finished Copper Thickness/Weight (O/L) 6 oz (177.4 ml) 2 oz (59 ml) 2 oz (59 ml)
Max Finished Copper Thickness/Weight (I/L) 6 oz (177.4 ml) 2 oz (59 ml) 2 oz (59 ml)
Min Panel Size 12″ x 18″ (30 x 46 cm) 12″ x 18″ (30 x 46 cm) 12″ x 18″ (30 x 46 cm)
Max Panel Size 21″ x 29″ (53 x 74 cm) 21″ x 29″ (53 x 74 cm) 18″ x 24″ (45 x 61 cm)
Smallest Mech Drill Diameter .0059″ (.150 mm) .005″ (.127 mm) .0059″ (.150 mm)
Smallest Laser Drill Diameter .004″ (.102 mm) .004″ (.102 mm) .003″ (.076 mm)
Max Through-Hole Aspect Ratio 10:1 10:1 10:1
Max Blind Via Aspect Ratio .75:1 .75:1 .75:1
Min Drill-to-Copper Clearance .006″ (.152 mm) .005″ (.127 mm) .008″ (.203 mm)
Min Trace and Space Width .003″ (.076 mm) .003″ (.076 mm) .0035″ (.089 mm)
Min Pad Size for Test .005″ (.127 mm) .004″ (.102 mm) .005″ (.127 mm)
Process Pad Diameter D + .012″ (.305 mm) (1-mil (.025 mm) annular ring) D + .010″ (.254 mm) (1-mil (.025 mm) annular ring) D + .014″ (.356 mm) (1-mil (.025 mm) annular ring)
Stacked Vias Yes Yes No
Min Wire Bond Pad Size > .004″ (.102 mm) > .003″ (.076 mm) .005″ (.127 mm)
Controlled Impedance Tolerance 10% 10% 10%
Solder Mask Registration .002″ (.051 mm) Within .001″ (.025 mm) Within .002″ (.051 mm)
Solder Mask Feature Tolerance .001″ (.025 mm) .001″ (.025 mm) .001″ (.025 mm)
Solder Mask Min Dam Size .004″ (.102 mm) .004″ (.102 mm) (SMT) .0035″ (.089 mm) (BGA) .005″ (.127 mm)
Min Diameter Rout Cutter .024″ (.610 mm) .024″ (.610 mm) .024″ (.610 mm)
Mech Routed Part Size Tolerance +/- 5 +/- 5 +/- 5
Laser Hole Location Tolerance .001″ (.025 mm) .001″ (.025 mm) .001″ (.025 mm)
Laser Routed Part Size Tolerance – Can only be done with panels <.032″ thick .001″ (.025 mm) .001″ (.025 mm) .001″ (.025 mm)
Bow and Twist Tolerance Per IPC Spec 7% 7% along rigid area
Thickness Tolerance 10% 10% 10%
Sequential Laminations 3 4 3
Conductive Filled Vias Yes Yes No
Non-Conductive Filled Vias Yes Yes Yes
Trusted by innovators

Engineers at the world’s most innovative DoD contractors choose Sierra Circuits for the highest quality MIL-PRF-31032 IPC 6012 class 3/ES PCB manufacturing, and assembly right here in the USA.

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Product Image 2: Aerospace & Defense PCBs

Sierra Circuits engineers have the experience to bring your aerospace and defense PCBs to life.

Whether you’re developing weapons systems of the future or you’re a DoD contractor looking to satisfy ITAR regulations, Sierra Circuits manufactures and assembles the most rugged, reliable mil-spec PCBs in America.

Ideal for:

  • DOD product designers developing systems for mission critical functions
  • Contract manufacturers who need fast, predictable lead times
  • Purchasing teams who require pricing and supply-chain transparency
  • Aerospace engineers looking to shore-up their supply chain troubles

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Sierra Circuits is
headquartered in Silicon Valley.
We welcome visitors at
our 70,000 sqft facility,
located at 1108 West Evelyn Avenue
in Sunnyvale, California.
Book a tour with an account manager today!
Let us introduce you to one of the most innovative communities of engineers and designers in the world.
We can help you plan your project from design to assembled board.

Manufacturing Equipment at Sierra Circuits

Our 70,000 sqft state-of-the-art campus in the heart of Silicon Valley contains the most advanced equipment required for the manufacture and assembly of your PCBs. Whether you’re looking for standard quick turn PCBs or boards with the tightest tolerances, made from exotic metals, there’s a reason Sierra Circuits leads the industry in quality and performance.

PCBs manufactured and assembled in the United States

Get started with Aerospace & Defense PCBs

Contact us today to find out how Sierra Circuits can help you achieve your objectives.

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Talk to a Sierra Circuits PCB Expert today

24 hours a day, 7 days a week.

Call us: +1 (800) 763-7503
Email us: through our Customer Care form