Why Obsolete Chips Are Still Used in Aerospace and Defense?

- July 21, 2025

In an age where technology advances at lightning speed, it might seem surprising that outdated or obsolete semiconductors still play a vital role in aerospace and defense systems. From fighter jets to satellites, these older components remain embedded in mission-critical equipment. But why?

Let’s explore why aging electronic components are still essential to modern defense systems and how this reality shapes supply chain strategies, procurement policies, and risk management in the defense and aerospace industry.

Proven Reliability in Harsh Environments

When it comes to aerospace and defense, reliability is non-negotiable. Systems must perform flawlessly in extreme environments, from the vacuum of space to the intense heat of combat zones.

Many of these obsolete electronic chips have already undergone rigorous military-grade testing and have proven stability over time. They're radiation-hardened, temperature-resistant, and capable of withstanding shock and vibration, making them ideal for mission-critical operations.

In contrast, newly developed chips often require years of testing and certification to meet the same standards, a delay that defense timelines simply can't afford.

Requalification Is Expensive and Time Consuming

Replacing an obsolete component with a newer version isn’t as simple as swapping it out. Every component in a defense-grade electronic system must be tested and validated through a process called requalification. This includes:

Environmental testing
EMI/EMC compliance
System-level integration
Certification from aerospace regulators

Requalification can take 3–5 years and cost millions of dollars. That’s why many OEMs and defense contractors choose to stick with the original, qualified parts, even if they’re technically outdated.

Stockpiling and Cloning for Continuity

To manage the obsolescence risk, aerospace companies often stockpile critical components during the initial production phase of an aircraft or satellite. These components can be stored in controlled environments for decades.

In addition to stockpiling, authorized cloning or form-fit-function (FFF) replacements are sometimes used. These are reverse-engineered components that match the original part’s specifications, allowing the system to remain fully functional without requalification.

Specialized Suppliers Fill the Gap

With major chip manufacturers discontinuing old product lines, a niche market of specialty electronic component suppliers has emerged. These companies:

Source end-of-life (EOL) and legacy semiconductors
Offer counterfeit detection services
Maintain access to aerospace-grade inventories
Build custom replicas when necessary

This market plays a crucial role in supply chain resilience, allowing defense programs to continue without costly redesigns or delays.

Longevity Beats Innovation in Defense

In consumer electronics, innovation is everything. In aerospace and military systems, the opposite is true, longevity, dependability, and maintainability are prioritized over performance gains.

Systems are often in service for 30–50 years, such as the F-16 fighter jet or GPS satellites. Keeping them operational requires ongoing access to the original electronic components, even if those parts are decades old.

The Bigger Picture: Lifecycle Management

Defense contractors and OEMs use strategies like obsolescence forecasting, lifecycle planning, and multi-sourcing agreements to minimize disruption. By understanding the full lifecycle of every component, they can plan for future shortages and ensure system readiness for years to come.

Conclusion

The continued use of obsolete chips in aerospace and defense is not a sign of stagnation, it’s a testament to the uncompromising standards of these industries. When human lives, national security, and billion-dollar equipment are at stake, the most important metric is trust, not novelty.

Whether you’re sourcing components for a satellite program or maintaining a fleet of aircraft, understanding this dynamic is essential for building reliable and resilient electronic systems.

To know more, watch our video : https://youtube.com/shorts/5GOYY8ceYVw?feature=share