Ruggedized communications router system

Modified commercial router for harsh environments

Application Notes


Re-use of an existing commercial router in this rugged environment was the key requirement. Necessary backwards compatibility requirements demanded that modifications to the system should be operating system agnostic and transparent to users. The project utilized commercial Cisco routers, chosen for their capability, high speed and reliability, which needed to be housed in packaging tested and qualified for extreme environments.


Elma performed a characterization study of the environmental limits of the Cisco router, including thermal analysis and resistance to high levels of shock and vibration. Elma’s packaging design team implemented board modifications such as conformal coating and component hold-down methods. They enhanced an existing rugged COTS 19” chassis, suited to shock isolation, increased cooling and system temperature monitoring. The system successfully passed all testing.