For those curious about the Black Box of an aircraft, more properly known as an aviation or flight data recorder, here’s a peek into one of them. These photos were taken at L-3 Aviation Recorders headquarters, in Sarasota, Florida, USA, for a Focus feature in Aerospace Singapore magazine Volume 3 No. 3 in 2010.

Aircraft aviation flight data recorder (commonly known as a Black Box)Aircraft aviation flight data recorder model FA2100 by L-3 Aviation Recorders.

A FA2100 flight data recorder (FDR) by L-3 Aviation Recorders, the largest manufacturer of such a device. Mandatory for every aircraft, this device makes cockpit voice and other flight data recordings, especially crucial in any air incident investigation. Designed to be very reliable and highly survivable, a FDR’s components are tested in various ways in extreme conditions at L-3 Aviation Recorders’ facility, including resistance to 3400G impact and 1100°C fire. It is actually painted a bright orange for better visual detection during recovery and has an underwater acoustic beacon with a six-year battery.

Aircraft aviation flight data recorder (puncture test)A puncture test rig at L-3 Aviation Recorders.

Shown in a puncture test rig, the Crash-Survivable Memory Unit (CSMU) has a protective casing made of stainless steel or titanium designed to survive flight and crash conditions as listed:

Operating Temperature -55 °C to +70 °C
Non-operating Temperature -55 °C to +85 °C
Operating Altitude -1,000 to 55,000 ft.
Operating Vibration DO-160C Para 8.5.2
Category C (random)
Penetration ED-55 500 lbs./ 10 ft. /¼-in. probe
Static Crush ED-55 5,000 lbs.
Fire Protection 50,000 BTU/ sq. ft. /hr. for 60 min. at 1100 °C; 10 hrs. at 260 °C
Impact ED-55 3,400 G, 6.5 ms, half-sine shock wave

Aircraft aviation flight data recorder (electromagnetic interference EMF)Flight recorder testing at L3 Aviation Recorders lab.

Electromagnetic interference test set up.

Aircraft aviation flight data recorder (vibration test)A vibration test set up for a aviation flight data recorder at L-3 Aviation Recorders.

Mounting of sensors for a vibration test.

Aircraft aviation flight data recorder (commonly known as a Black Box)An aircraft black box, or otherwise known as a flight data recorder, or an aviation recorder with test instruments at L3 Aviation Recorders lab in Florida US. The current solid state model in the middle is flanked by older versions. http://www.aerophotoworks.com/blog/2014/3/aviation-recorder-flight-data-recorder-black-box

The current solid state flight data recorder in the middle with the Crash-Survivable Memory Unit detached, flanked by older models.