At MSI-DFAT Services (Maryland Sound International Direct Field Acoustic Services), NETGEAR AV switches provide the robust network foundation for acoustic qualification testing of satellites and aerospace components. This mission-critical application demands flawless performance to ensure multi-million-dollar satellites can withstand the extreme acoustic environment of rocket launches
IN THIS ARTICLE
Industry:
Spacecraft acoustic testing
Company website:
msidfat.com
Location:
Baltimore, USA
MSI specializes in acoustic qualification testing, also known as Direct Field Acoustic Testing (DFAT) for the aerospace industry, providing an alternative to traditional fixed acoustic chambers. Instead of requiring satellite manufacturers to transport their expensive payloads (often valued at $500 million or more) to remote testing facilities, MSI brings its mobile sound systems directly to the manufacturing sites.
The company’s innovative approach uses professional, purpose built audio equipment configured in a circular array of 10 to 50 feet tall, surrounding the satellite with speakers designed by MSI, to recreate the intense acoustic environment of a rocket launch. This testing is critical as satellites must prove they can withstand sound levels of 130-150 decibels, a level that can lead to eardrum perforation and irreversible hearing loss in humans, before being approved for space missions.
Arthur Isaacs, MSI’s lead audio engineer, emphasized the scale: “We’re typically running anywhere from 80 to 300 amplifiers in a single system. Each one needs both audio signal and control data, and everything has to work flawlessly because there’s no room for error when you’re testing a half-billion-dollar satellite.”
MSI’s transition from analog to digital systems created complex networking requirements that traditional solutions couldn’t adequately address. The company needed to manage massive numbers of networked devices while maintaining the reliability demanded by aerospace applications.
The technical challenges were substantial: supporting 80-300 networked amplifiers per installation, distributing high-quality digital audio across large speaker arrays, managing control data for precise acoustic calibration, integrating multiple device types including serial-controlled equipment, ensuring zero-tolerance reliability for mission-critical testing, and providing remote monitoring capabilities from safe distances during extreme-volume tests.
The networking infrastructure had to seamlessly handle all those data types while supporting the rapid reconfiguration capabilities that modern aerospace testing demands. Traditional networking approaches required extensive manual cable management and offered limited flexibility for system modifications.
MSI selected NETGEAR M4250 series switches as the backbone of their mobile acoustic testing systems, specifically choosing the platform for its AV-optimized features and robust technical support. The solution centers on NETGEAR’s AV Line switches with pre-configured audio networking profiles that simplified deployment and configuration.
The network architecture features a distributed design with multiple M4250 switches (both 48-port and 12-port models) connected via fiber optic links to a central control room. In MSI’s largest installation, 16 NETGEAR switches manage the complete system infrastructure. Each switch handles approximately 24 amplifiers plus additional monitoring and control devices, creating a scalable architecture that can adapt to different testing requirements.
The system leverages NETGEAR’s AV-specific features including pre-built profiles for audio applications, simplified VLAN configuration for separating audio, control, and communication traffic, auto-trunking capabilities for seamless multi-switch coordination, and integrated support for both networked and legacy serial devices through strategic computer placement.
A critical component of the solution is the comprehensive technical support provided by NETGEAR, with dedicated ongoing guidance for complex configurations. This support proved essential as MSI developed and refined their networking approach across multiple installations.
The deployment also utilizes NETGEAR Engage management software, providing centralized control and monitoring of all switches from a single interface. This eliminates the need to manage individual device browsers and provides complete network topology visibility, which is crucial for troubleshooting in mission-critical environments.
Products used
The NETGEAR-based solution has transformed MSI’s operational capability, supporting three active mobile systems with proven reliability in demanding aerospace testing environments. The network infrastructure has enabled MSI to maintain their position as industry leaders while expanding their service capabilities.
The implementation delivered multiple operational benefits including dramatic reduction in setup complexity with digital reconfiguration replacing manual cable management, centralized monitoring and control through NETGEAR Engage software, scalable architecture supporting systems from 80 to 300+ amplifiers, and robust performance during extreme acoustic testing conditions.
The technical support relationship proved equally valuable, with continuous consultation enabling MSI to optimize their configurations across multiple installations. This ongoing partnership has been instrumental in MSI’s decision to standardize on NETGEAR equipment, replacing their previous networking infrastructure with a more AV-optimized solution.
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