PEM Qualification & Screening for
Hi-Reliability Components
PEM Qualification and Screening Services
Bridging the Gap Between COTS Performance and Spaceflight Reliability
PEM qualification and screening ensure that plastic-encapsulated microcircuits (PEMs)—the dominant packaging format for modern integrated circuits—meet the stringent reliability requirements of space, aerospace, and defense applications. At AAA Engineering & Test Lab, we deliver comprehensive, in-house PEM qualification and screening services aligned with NASA PEM-INST-001, MIL-PRF-38535 Class N/Y, and MIL-STD-883 test methods.
Our fully integrated capabilities enable customers to qualify, screen, and certify commercial-off-the-shelf (COTS) PEMs for mission-critical use without the extended lead times and fragmentation common with legacy providers.
PEM Qualification & Screening Capabilities
PEM Qualification vs. PEM Screening
PEM Qualification
- Establishes family-level suitability
- Uses historical data, similarity analysis, and accelerated stresses
- Supports new designs, obsolescence mitigation, and flight acceptance
PEM Screening
- Detects and removes lot-specific defects
- Applies 100% electrical and environmental stress
- Reduces early-life failures prior to integration
Both are tailored by mission risk class in accordance with PEM-INST-001 and MSFC-STD-3012.
AAA Engineering & Test Lab provides turnkey PEM qualification services supporting New Space programs and DoD Class N/Y systems:
- Part Categorization and Similarity Analysis
Evaluation against PEM-INST-001 classifications using historical qualification data. - Risk-Based Test Tailoring
Mission-specific flows incorporating thermal, mechanical, humidity, and radiation stresses per MSFC-STD-3012. - Lot Traceability and Identity Verification
Documentation audits, external visual inspection, and X-ray per MIL-STD-883 Method 2012. - Destructive Physical Analysis (DPA)
Construction review via decapsulation, bond pull, die shear, and cross-sectioning per MIL-STD-1580. - Environmental Robustness Assessment
Assembly simulation, stress testing, and reliability modeling to forecast lifetime performance.
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How PEM Qualification and Screening Work
AAA Engineering & Test Lab executes PEM qualification and screening using a tiered, evidence-based framework aligned with NASA and DoD requirements.
1. Part Selection and Identity Verification
- Part categorization (e.g., QML Class N/Y under MIL-PRF-38535)
- Traceability review and documentation audit
- Radiographic inspection (X-ray) to verify internal construction
2. Preconditioning and Environmental Stress
- Moisture sensitivity level (MSL) bake/soak per J-STD-020
- Temperature cycling and humidity bias (THB/HAST) to provoke latent defects
3. Electrical Screening and Burn-In
- Baseline and post-stress parametric testing
- Static and dynamic burn-in (160–1000 hours at 125 °C)
- Removal of early-life and process-induced failures
4. Destructive Physical Analysis (DPA)
- Decapsulation (jet-etch or laser)
- Wire bond pull and die shear testing
- Cross-section and construction analysis
This multi-layer approach combines 100% screening with destructive subgroup testing to quantify risk and verify construction integrity, with tailoring based on mission class (e.g., full qualification for crewed systems versus similarity-based approaches for CubeSats).
Key Failure Mechanisms Addressed
PEM qualification targets physics-driven risks inherent to non-hermetic packaging:
Moisture-Induced Damage
Moisture absorption leads to vapor expansion during reflow, causing popcorning, delamination, or wire lift. Mitigated through MSL classification, preconditioning, and CSAM inspection.
Electrochemical Corrosion and Leakage
Moisture and ionic contamination enable aluminum or copper corrosion and dendritic growth, shifting electrical parameters. Addressed using unbiased HAST/THB and cleanliness controls.
Thermo-Mechanical Fatigue
CTE mismatches between polymer mold compound and silicon drive fatigue in wire bonds and interconnects. Evaluated through extended temperature cycling per MIL-STD-883 Method 1010.
Supply Chain Variability and Counterfeit Risk
Frequent material changes and brokered sourcing introduce risks of out-of-family dies or remarking. Mitigated through radiography, decapsulation, and AS6081-aligned authenticity verification.
Early-Life Defects
Process variability results in infant mortality. Identified and removed through 100% burn-in and subgroup DPA.
These mechanisms are evaluated to support long-term reliability targets exceeding 10⁶ hours MTBF in LEO and GEO mission profiles.
Test Flows and Standards
Test severity is scaled by mission risk and program requirements.
Screening (100% Lot)
- External visual inspection
- X-ray inspection
- Baseline electrical testing
- Bake (24 h at 125 °C)
- Temperature cycling (300 cycles, −65 °C to +150 °C)
- HAST (85 °C / 85% RH, 96 h)
- Burn-in (240 h at 125 °C, static/dynamic)
- Final parametric verification
Qualification (Family or Lot)
- Preconditioning per J-STD-020
- Extended temperature cycling (up to 1000 cycles)
- THB/HAST (up to 1000 h)
- Radiation testing when required
- Similarity justification per PEM-INST-001
DPA Subgroup
- Decapsulation
- Bond pull and die shear (MIL-STD-883 Methods 2011/2019)
- Dye penetrant and cross-section analysis
Standards applied include MIL-STD-883, MIL-PRF-38535, J-STD-020, and MSFC-STD-3012A, with audit-ready reporting to support DLA and program certification.
Facility and Instrumentation
AAA maintains controlled facilities and instrumentation to execute PEM qualification and screening flows under engineering oversight, with traceable documentation and audit-ready reporting.
Environmental Stress and Preconditioning
- Temperature Humidity Bias (THB) / Highly Accelerated Stress Test (HAST) capability (program-defined conditions and durations)
- Thermal cycling and temperature exposure for workmanship and package stress evaluation
- Preconditioning workflows aligned to the qualification flow and sample handling requirements
Electrical Screening and Burn-In
- Automated electrical testing and screening aligned to test flow requirements
- Burn-in capability for early-life defect exposure and lot risk reduction
- Fixtures and adapters configured per device package and pinout requirements
Destructive Physical Analysis (DPA) Support
- Decapsulation and internal visual inspection workflows when required
- Bond pull / die shear / cross-section support as part of subgroup analysis
- Photographic documentation and controlled sample tracking
Inspection, Handling, and Controls
- Receiving inspection and controlled sample traceability
- ESD controls and handling discipline aligned to hi-rel work
- Controlled documentation workflows supporting audit and program reviews
Optional Program-Specific Add-Ons
- Radiation testing coordination when required by the program flow (scope and approach confirmed during planning)
- Tailored subgroup sampling plans and reporting package formatting for program reviews
Our PEM Services
AAA Engineering & Test Lab leverages decades of expertise in microelectronics reliability and failure physics to support NASA, DoD, and DLA programs.
- Full Turnkey Qualification
Family-level validation using historical data, similarity analysis, and PEM-INST-001 stresses. - Lot Screening and DPA
100% electrical screening with destructive analysis to identify defects and authenticity risks. - Tailored Test Plan Optimization
Mission-specific flows balancing MIL-STD-883 stresses with physics-of-failure modeling. - Failure Analysis and Design Feedback
Root-cause analysis using SEM/EDX and statistical methods to improve long-term reliability. - Strategic Consulting
Guidance on J-STD-020 handling, MSFC-STD-3012 derating, and MIL-PRF-38535 compliance.
Discover how AAA Engineering & Test Lab can support your next PEM qualification effort.
What We Need to Quote and Schedule PEM Qualification
To scope the correct qualification or screening flow and provide an accurate schedule, please include:
- Part numbers and component family (family-level qualification vs lot screening)
- Intended application and mission class (space, defense, avionics, or other hi-rel)
- Applicable requirement set (PEM-INST-001, MSFC-STD-3012, MIL-PRF-38535 Class N/Y context, or program-defined flow)
- Lot and quantity available for screening and destructive subgroup analysis
- Traceability available (authorized distribution vs brokered sourcing history)
- Any prior test history (electrical, burn-in, environmental stress, radiation, anomalies)
- Schedule constraints and reporting needs (qualification package vs lot disposition summary)
What You Receive
AAA delivers an audit-ready PEM qualification and screening package designed for engineering and quality reviews, including:
- A documented test flow aligned to your program intent and requirements
- Baseline and post-stress electrical results with pass/fail disposition and exceptions
- Environmental and burn-in run documentation and configuration notes
- DPA subgroup findings with photos and observations when included (decapsulation, bond pull, die shear, cross-section)
- Clearly documented deviations, anomalies, and risk indicators
- A reporting package suitable for lot disposition, qualification evidence, or anomaly investigation workflows
Applications
- COTS-to-hi-rel qualification for New Space and defense programs
- Lot screening and early-life failure risk reduction prior to integration
- Supplier validation and part family suitability assessments
- Obsolescence mitigation and alternate sourcing validation
- Failure analysis support when PEM construction or moisture sensitivity is suspect
Why Customers Choose AAA Engineering
- American Owned: We are 100% American owned, and operated by veterans of the US Air Force, US Army, US Marines, and US Navy.
- Proven Expertise: 15+ years of upscreening and component data.
- Technical Authority: Skilled in MIL-STD, NASA, and AS6171 standards.
- Certified Excellence: ISO/IEC 17025, AS6081, AS6171, ISO 9001/AS9100, ANSI/ESD S20.20, ITAR-registered.
- Trusted Results: Transparent, traceable data logs for reliability.
- Scalable Solutions: Supports prototype to production volumes.
Ready To Qualify Your Plastic Encapsulated Microcircuits?
Contact our PEM Qual engineering team today to ensure your components can stand up to the most rigorous conditions and deliver mission success.
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