1. stacosystems
One Step Ahead
Thank you for attending.
The following is a brief introduction to Staco’s
Sub-Systems Division…
About Staco Systems
Sub-Systems Division
Core Competencies
Example Sub-Assemblies
3. stacosystems
One Step Ahead
The Company
Who We Are
• Founded in Costa Mesa, California in 1958
• Name change from Staco Switch to Staco Systems in 2008 to reflect expanding
product offerings.
• Staco Systems’ home is now a modern 40,000 sq ft facility in the City of Irvine.
• Proudly serves the aerospace, military, law enforcement, public safety, industrial
markets, and nuclear power industry in the US and worldwide.
We have the experience and qualified resources to
support any size project you may have.
We invest the time and effort to get to know you, your
business, and goals.
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4. stacosystems The Company
Product Time Line
One Step Ahead
1960 1962 1967 1978 1986
Series 30, 1M Series 40 Custom Multi-Pole Series 50 Series 93, 99
Fokker F-27 Lockheed P3 Switches Boeing E-3A British Aerospace
McDonnell Douglas Hawk 200
F-4
1988 1989 1991-92 1995-98 2009-2010
Series 97 Matrix Series 80, 90 Series 90 Keypads Series 100
Northrop B2 Aeritalia AMX Boeing E-8C Keyboards Series 200
Lockheed F-22 Sub-Systems
Digital Dimming
Module
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5. stacosystems The Company
Organization
One Step Ahead
Switch Products Division
Data Entry Solutions Sub-Systems
Division Division
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7. stacosystems
One Step Ahead
Sub-Systems Division
WHY SUB-SYSTEMS
In response to frequent customer requests for
value-added assemblies, the Sub-Systems Division
was established in 2009 and leverages Staco’s
core competencies, developed over 50 years of
electro-mechanical and optical design and
manufacturing experience.
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8. stacosystems
One Step Ahead
Sub-Systems Division
VALUE PROPOSITION
We have the design, manufacturing and supply
chain management expertise to coordinate and
integrate the numerous components that sub-
assemblies require, allowing you to focus on your
core competences, and keeping your production on
time, and on budget.
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10. stacosystems
One Step Ahead
Core Competencies
Engineering, Design & Development
• Engineering, design and development resources
and services include…
• SolidWorks 3-D CAD Software
• Optics Engineering for NVIS/Custom Lighting
• Electrical & Mechanical Engineering
• Human Factors Engineering
• Optics Design Laboratory
• Environmental Test Laboratory
• ATP/ATR, QTP/QTR Development
• Field PDR/CDR/Install Support
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11. stacosystems
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Core Competencies
Manufacturing
All activities are consolidated under one roof in
our new 40,000 square foot facility, including
the following manufacturing processes…
• Machine shop, including modern CNC
equipment
• Mold Shop
• Paint Shop
• Optical Laboratory for chromaticity and NVIS
in-process testing
• Cell based manufacturing structure
• Automated testing
This vertical integration provides Staco with full
control of the production cycle
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12. stacosystems
One Step Ahead
Core Competencies
Testing
• All sub-assemblies are prototyped and subjected to thorough design testing
to prove compliance with customer’s specifications before release to
production. Comprehensive Design Test Reports are provided on request.
Production units are 100% tested to custom ATP’s before shipping.
• Staco Systems’ long pedigree of QPL Certification and continued
compliance testing is the basis of our infrastructure for providing all of your
custom test needs.
• Staco Systems is capable of performing most testing in-house. Specialized
testing is performed by local test lab partners.
Optics Testing
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13. stacosystems
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Core Competencies
Quality Assurance
Staco Systems is a manufacturer of high-
reliability, precision electro-mechanical and optical
products and assemblies. As such, we are ISO 9001:2000
and AS9100:2004 Rev.C Certified and we routinely
manufacture products that comply with the following
military, industry and customer standards and practices:
• MIL-S- 22885
• MIL-STD-45662A
• MIL-STD-7788G
• IPC-A-610
• MIL-I-45208
• Certified and calibrated light labs for MIL-L-85762A, MIL-STD-
3009, MIL-C-25050 (SAE-AS25050) measurements
• Customer certification/source
approvals, Gulfstream, ARINC, Raytheon, BAE Systems, EADS
Eurocopter
• QPL Approvals to all branches of the US Armed Forces
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14. stacosystems Sub-Systems Division
Assemblies and LRUs
One Step Ahead
• Build-to-Print & Custom Designs
Typical Features..
Metal and Illuminated Faceplates
NVIS and Commercial Lighting
COTS Components, Including…
Electromechanical switches and controls
Integrated keyboard/keypad functions
Annunciators (warning/caution/advisory)
Harnessing/Cabling/Connectors
Enclosed or Open Frame
• Industry Standard Interfaces
Integrated electronics for electrical interface and data
bussing within a new or existing system
RS232 ARINC 429
RS422 MIL-STD-1553
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16. stacosystems Sub-Systems Division
One Step Ahead
Switching Panel with
Illuminated Faceplate and
NVIS-Compatible Legends
Prewired to Rear
Connector
(eg: Sub-D, MIL3899, etc.)
Aluminum
Enclosure Lighted PB
(Sealed if Req’d)
Switches
(MIL-PRF-22885)
Rotary Switch
Toggle Switches (MIL-DTL-3786)
(MSxxxxx as req’d)
Data Port
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17. stacosystems Sub-Systems Division
One Step Ahead
Staco Systems
Customer Conceptual Conceptual
Requirement Arrangement
Chaff & Flare
Dispense Control Arrangement of
Unit COTS
components
wired to rear
Mil Spec
Connector
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18. stacosystems Sub-Systems Division
One Step Ahead
Power Select
Module for a new
Laptop Docking
Station for Airbus
A320 EFB System
Custom momentary (dome) switch with LED illuminated keys
Pushbutton keys and face plate legends illuminated to stringent Airbus
ABD0023 requirements
Electrical, mechanical and environmental performance to customer and Mil
Spec requirements
Custom light plate mounted wire switch guard
Very low power consumption when fully lit (< 80mA at 12Vdc)
All components (switches, indicators, electronic components and rear
connector) connected directly to internal PCB for hi-reliability performance
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19. stacosystems Sub-Systems Division
One Step Ahead
Broadband Control Panel
for In-Flight Wi-Fi
Connectivity System
Build-to-Print
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20. stacosystems Sub-Systems Division
One Step Ahead
Datalink Panel for
Airborne Communication
System
• Illuminated Faceplate and NVIS-Compatible Legends
• Toggle Switches (MIL Spec)
• Prewired to Rear Connector (MIL Sub D)
• Enclosed
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22. stacosystems Sub-Systems Division
One Step Ahead
19” Rack Mount
Illuminated Switching
Panels with NVIS-
Compatible Faceplates
and Legends
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23. stacosystems Sub-Systems Division
One Step Ahead
Control Panel for Laser
Imaging System on EC-145
Helicopter
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24. stacosystems Sub-Systems Division
One Step Ahead
Pod Control Panel for Laser Imaging System
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26. stacosystems Sub-Systems Division
One Step Ahead
ECS Panel for Bell 206 Helicopter
Part of STC Package
Metal
Bezel, NVIS Keys
for
Military Aircraft
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27. stacosystems Sub-Systems Division
One Step Ahead
Upper Console Panels
for UH-60M Blackhawk Trainer
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28. stacosystems Sub-Systems Division
One Step Ahead
Engine Order Telegraph (EOT) Panels
for Nimitz-Class Nuclear Powered With Series 200
Aircraft Carriers Switches
With Series 50
Switches
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29. stacosystems Sub-Systems Division
One Step Ahead
Bridge Manual Pump Controller Panels for
Nimitz-Class Nuclear Powered Aircraft
Carriers
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30. stacosystems Sub-Systems Division
One Step Ahead
Cabin Monitoring
Panels
for
Commercial
Regional Aircraft
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31. stacosystems Sub-Systems Division
One Step Ahead
Pakistan Air Force
•SAAB MFI-17 Trainer
•Lighted Pushbutton Switching Assembly
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32. stacosystems Sub-Systems Division
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Fujitsu
Operation Panel
Project:P-3C
(Maritime patrol
aircraft, designed
by Lockheed)
Application:FLIR
(AN/AAS-36)
recording system
(re-design)
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33. stacosystems Sub-Systems Division
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• Lighted faceplate with integrated custom keypad
• Indicator lights (3) sunlight readable and NVIS ‘Friendly’
• 20-Character dot-matrix alphanumeric display
• Interconnecting PCB with edge-connector (for flex cable by
others)
• Indicator lights will be one each NVIS Green ‘A’, NVIS Green
‘B’ and NVIS ‘Blue’ (aka ‘Air Force Blue’)
• Indicator light legends (NUM, LET and COM) always lit
• Supply voltage (lighting): 5Vdc
• Toggling of indicators to be implemented by Karem (ie; logic
connecting indicators to NUM/LETTR/COMM key)
• Logic control signals to dot-matrix display to be provided by
Karem
• Display readout = Lat/Long to 5 decimal places
• 5/8‛ square keys OK
• Keypad, indicator lights and display to be connected to a PCB
with traces to an edge connector
• DZUS fasteners required, location TBD
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34. stacosystems Sub-Systems Division
One Step Ahead
Sierra Nevada Corporation
•5.75‛
STANDARD DZUS Korean A/F Project
FORM FACTOR
•BASIC REQUIREMENTS •A •B •C •D •E
•F •F
• USB INTERFACE WITH D-SUB OR
CIRCULAR CONNECTOR 1 2 •F •G •H •I ••D
J
•F •F
• NVIS COMPLIANT
3 4 •K •L •M •N •O
• DO-160 COMPLIANT
•1 •2 •3
• OPERATING TEMPERATURE - •P •Q •R •S •T
40 C TO +70 C PER MIL-STD-810. •4 •5 •6
• TSO NOT REQUIRED
•7 •8 •9 •U •V •W •X •Y
•SP •DE •EN
•BACKLIT KEYPAD •. •0 •± •Z •/ C L T
•‚X-BOX STYLE‛ POINTING DEVICE
•RUBBERIZED PAD
•WORKSTATION CONTROL PANEL
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35. stacosystems Sub-Systems Division
One Step Ahead
Driessen Aerospace
Airbus Galley Power Distribution
and Protection Panel
•Redesign Project
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37. stacosystems Sub-Systems Division
One Step Ahead
L-3 Wescam: Algeria Project
• Lighted faceplate (1)
• Single Phase Thermal Circuit Breakers (6)
• Mil38999 41-Pin Circular Military Connectors (5)
• Sub-D 9-Pin Connector (1)
• Interconnecting Wiring (assume all connector pins
populated for ROM pricing)
• Enclosure (unsealed)
• Lighting to be sunlight readable (non-NVIS)
• Supply voltage (lighting): 28Vdc
• Mounting holes for surface mounting (under seat)
• Overall dimensions of panel TBD (‘as small as
possible’)
• No EMI/RFI Shielding requirements
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38. stacosystems Sub-Systems Division
One Step Ahead
Komatsu America, Inc.
Camera Control Panel
Mining Equipment
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39. stacosystems Sub-Systems Division
One Step Ahead
To Summarize…
• Build-to-Print & Custom Designs
Typical Features..
Metal and Illuminated Faceplates
NVIS and Commercial Lighting
COTS Components, Including…
Electromechanical switches and controls
Integrated keyboard/keypad functions
Annunciators (warning/caution/advisory)
Harnessing/Cabling/Connectors
Enclosed or Open Frame
• Industry Standard Interfaces
Integrated electronics for electrical interface and
data bussing within a new or existing system
RS232 ARINC 429
RS422 MIL-STD-1553
3/19/2012 StacoSystems Confidential 39
