Case Study: BAE Systems achieves 98% wiring reduction in turret control computer with Zuken's CADSTAR

BAE Systems uses CADSTAR to help reduce turret control computer wiring by 98%

BAE Systems undertook a midlife update of the Turret Control Computer (TCC) for its AS90 howitzer to address obsolescence, cut assembly/manufacturing costs and dramatically reduce the extensive wiring that connected nine PCBs to external connectors. To meet these goals and a demanding schedule, BAE Systems chose Zuken’s CADSTAR PCB design environment to drive the redesign.

Using Zuken CADSTAR (including its Constraint Manager and advanced routing tools), the team designed a 24‑layer flexi‑rigid PCB with four flexible tails that fold to mate the front‑panel connectors, preserving signal integrity with tightly matched differential pairs and shielding. Zuken’s solution helped BAE Systems cut TCC wiring by 98%, reduce assembly time from about two weeks to just a few hours, and complete the update 12 months ahead of the original 36‑month schedule.

BAE Systems

Paul Carr

Leading Draughtsman