A standard you can't ignore

In the high-stakes world of search and rescue (SAR) aviation, there’s no room for compromise. When an aircraft takes off on a life-saving mission, the onboard systems must perform flawlessly under the most extreme conditions. Whether it’s freezing temperatures, severe turbulence, or electromagnetic interference, equipment failure can lead to mission failure – and in SAR operations, that can mean the difference between life and death. That’s why DO-160G testing isn’t just important; it’s essential.

DO-160G isn’t merely another industry standard. It’s the gold standard for environmental testing of airborne equipment. Yet, some SAR avionics systems are being installed without going through this critical testing. And while skipping this step may save time or cut costs in the short term, it introduces risks that no SAR professional should be willing to take.

DO-160G TESTING: MORE THAN JUST A STANDARD

The DO-160G standard is a rigorous, industry-accepted protocol developed by the RTCA. It includes a comprehensive suite of tests designed to evaluate how avionics equipment responds to the unique challenges of the airborne environment. From temperature extremes and rapid altitude changes to electromagnetic interference and vibration, DO-160G replicates the harsh conditions aircraft and their systems will face in real-world operations.

For SAR missions, where aircraft often operate in remote, challenging locations, equipment reliability is paramount. Systems must withstand everything from high heat during desert operations to freezing conditions in arctic rescues. If a piece of equipment fails in these environments, the mission – and the lives of those on board – are at risk.

THE PERILS OF SKIPPING DO-160G TESTING

Despite its importance, DO-160G testing isn’t mandated by regulatory authorities. It’s not a legal requirement, which can tempt some manufacturers to bypass it in favour of faster development timelines or lower costs. However, this is a risky move – one that could lead to disastrous consequences.

Consider a recent real-world scenario where a ground-based system, claimed by its manufacturer to be suitable for airborne use, was functionally tested on an aircraft. The system had never been through DO-160G testing, and the supplier had not accounted for the unique stresses and needs of the airborne environment. Once activated in flight, a number of critical onboard avionics systems of the host aircraft immediately malfunctioned, causing major safety concerns. Thankfully, the aircraft landed safely, but the system was immediately rejected from further evaluation.

This incident serves as a stark reminder: just because a system works perfectly well on the ground doesn’t mean it’s fit for use in the air. The airborne environment is far more demanding, and without the validation provided by extensive testing, you’re left with unknowns. When lives and mission success are on the line, uncertainty is a luxury no SAR operator can afford.

WHY DO-160G MATTERS IN SAR OPERATIONS

SAR missions are unpredictable and often take place in the most challenging environments. Whether responding to natural disasters, locating lost hikers in mountainous terrain, or conducting maritime rescues in stormy seas, SAR aircraft must be equipped with systems that can withstand whatever the mission throws at them.

This is where DO-160G testing proves invaluable. By subjecting avionics equipment to a broad range of environmental tests, DO-160G ensures that systems will continue to perform reliably in the face of extreme conditions. Testing covers 23 different environmental factors, including temperature variation, vibration, humidity, water ingress, and electromagnetic interference. The thoroughness of these tests means that equipment certified under DO-160G has been proven to work in scenarios that are far from ideal.

For SAR operators, the stakes are too high to gamble on untested systems. Imagine flying into a hurricane zone to rescue stranded civilians only to have your navigation system fail due to electromagnetic interference generated by a non-qualified ancillary system. Or picture yourself on a mountain search mission in subzero temperatures, only for a communications system to falter because it couldn’t handle the cold. DO-160G certification ensures these failures won’t happen.

THE COMPETITIVE LANDSCAPE: TESTED VERSUS UNTESTED SYSTEMS

There are systems available on the market today which are not DO-160G tested but are claimed by their manufacturers to be suitable for airborne use. Some of this equipment might come with a lower price tag or shorter lead times, making them attractive at first glance. But without testing and certification, there’s no guarantee that these systems will function correctly and safely when subjected to realworld conditions. Subsequently significant time and resources may be expended after the initial purchase in bringing these systems up to a safe operational level, if that’s even possible. On the other hand, equipment that has undergone testing offers peace of mind. When you choose a DO-160G-tested system, you’re not just investing in hardware – you’re investing in reliability, safety, and mission success. That’s the kind of value that far outweighs any initial cost savings from cutting corners on testing.

CASE IN POINT: PROVEN VERSUS PROMISED PERFORMANCE

The earlier example of the ground-based system causing malfunction in flight is just one of many stories illustrating the dangers of untested equipment. In that case, the supplier promised that their system would perform, but it hadn’t been subjected to any formal testing. The result was a failure that jeopardized not only the mission but the safety of the aircraft’s crew. Suppliers may also claim their systems completed DO-160G testing, but upon closer inspection have only subjected the unit to mild categories of testing, or a very limited subset of tests. It is important for both the integrator and operator to fully assess both category level and type of testing are suitably appropriate.

By contrast, fully DO-160G-tested systems provide assurance. They’ve been rigorously evaluated to ensure that they perform in the harshest environments. This is crucial in SAR operations, where equipment failures can lead to delays, missed rescues, or worse.

WHAT’S THE BOTTOM LINE?

In the aviation industry, and particularly in SAR, reliability isn’t a luxury – it’s a necessity. DO160G testing is not just about checking off a box on a compliance list; it’s about ensuring that when the mission begins, your equipment is up to the challenge.

Untested systems may work fine in controlled conditions, but in the real world, you need equipment that has been proven to perform. When lives are at stake, there’s no room for compromise. DO-160G testing ensures that your avionics systems are ready for the mission – no matter how extreme the environment. After all, in SAR operations, performance isn’t optional; it’s everything.

When you choose a DO-160G-tested system, you’re not just investing in hardware – you’re investing in reliability, safety, and mission success.