AEROSPACE ELECTRONICS

Calpak USA holds AS9100 Rev. D certification with full-scope coverage across our entire Hawthorne, California facility — from design through manufacturing, assembly, and test. This means every aerospace assembly we produce is governed by the same certified quality management system, unlike some contract manufacturers that only certify a subset of their operations. Combined with ITAR registration, IPC Class 3 workmanship capability, IPC-certified operators and inspectors, and over four decades of aerospace manufacturing experience, Calpak USA meets the qualification requirements of prime aerospace contractors and government programs throughout California.

AS9100 Rev. D builds on ISO 9001 by adding aerospace-specific requirements that directly reduce program risk. These include formalized risk management processes, configuration control procedures that prevent unauthorized design changes, product safety protocols, and counterfeit parts prevention measures per AS6174 and AS6081. For your program, this means every assembly from Calpak USA is produced under documented procedures for first article inspection per AS9102, nonconformance disposition with root cause analysis, and customer flowdown requirement management. The certification is maintained through annual third-party audits, ensuring continuous compliance — not just a point-in-time assessment.

Yes. Calpak USA performs first article inspections per AS9102 as a standard part of our aerospace program management process. FAI documentation includes full dimensional verification, material and process certifications, component traceability to lot and date codes, and functional test results. FAI packages are delivered in the format required by your quality system — whether that is AS9102 Form 1/2/3, a customer-specific template, or an electronic format. Our quality team at our Hawthorne, California facility coordinates FAI scheduling with your program manager to align with production milestones and contract deliverables.

Calpak USA performs and coordinates environmental stress screening tailored to each aerospace program's requirements. Common screens include thermal cycling across military and aerospace temperature ranges such as minus 55 to plus 125 degrees Celsius, random vibration testing per MIL-STD-810 profiles, and powered burn-in to precipitate infant mortality failures before assemblies ship. For HALT and HASS protocols, we coordinate with accredited third-party environmental test laboratories in the Southern California area. All screening data is documented and included in the deliverable data package with pass-fail disposition per your program's acceptance criteria.

Calpak USA is registered with the Directorate of Defense Trade Controls and maintains strict ITAR compliance at our Hawthorne, California facility. All ITAR-controlled technical data — including design files, manufacturing documentation, test procedures, and firmware — is handled exclusively by US persons. Physical facility access is controlled with badge entry, visitor logs, and escorted access for non-employees. Data is stored on access-controlled servers with role-based permissions. Non-disclosure agreements are executed before any proprietary data exchange. These protocols apply to all California aerospace and defense programs processed through our facility.

Yes. Calpak USA operates dedicated prototype and production assembly lines within our single Hawthorne, California facility, supporting aerospace programs from initial engineering builds through sustained full-rate production. During prototyping, our engineering team provides DFM and DFT feedback to optimize designs for manufacturing yield and test coverage. When programs transition to production, all tooling, stencils, validated solder profiles, and test fixtures carry forward — eliminating the re-qualification cycle that occurs when separate prototype and production vendors are used. This single-facility model satisfies AS9100 Rev. D requirements for configuration-controlled manufacturing across the full program lifecycle.