In designing avionics electronics packages, four areas of engineering need to come together and work concurrently as a team. These are electronic, electro-mechanical packaging, thermal and finally vibration engineers. Often times, thermal and vibration analyses are done only as an afterthought through experimental means to ensure Federal Aviation Authority (FAA) Federal Aeronautics Regulations (FAR) and / or ARINC standards.

In this paper, the mechanics and thermal design procedure and calculations (based on both analytical means and finite element methods) of an airborne ARINC 746 Cabin Telecommunications Unit (CTU) are discussed along with the relevant FAR’s, as well as, ARINC standards are considered. Finally, reliability and failure rates of components and their effects on the performance of the system are studied.

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