U.S. Congress to Approve Funds for R&D on Lead-Free Electronics and Defense
By Chris Mitchell, vice president, global government relations
Key Summary
• Congress is poised to approve $5 million for R&D on lead-free electronics in mission-critical defense applications
• The aerospace, defense, and high-performance sectors lack sufficient reliability data to fully transition to lead-free technologies
• The commercial electronics industry has already moved largely to lead-free materials due to health and environmental concerns
• IPC and nearly 30 partners advocated for this funding as seed money for a larger multiyear R&D effort
• IPC supports a long-term public-private program to close the lead-free data gap and strengthen U.S. defense readiness
In a win for U.S. taxpayers, defense readiness, and the electronics industry supply chain, the U.S. House and Senate are poised this week to approve a defense spending bill that includes $5 million for research and development on the issues surrounding lead-free electronics in mission-critical applications. President Trump is expected to sign the measure within hours after its passage. IPC and nearly 30 of its members and allies lobbied for these funds, which are “seed money” for a longer-term R&D effort. The need for these funds may be unfamiliar to the general public, but for the aerospace and defense industries, especially, this is a big deal. Over the last 15 years, the commercial electronics industry has largely phased out its use of lead (Pb) in the manufacture of electronic components and circuit assemblies, due to lead’s harmful effects on human health and the environment. However, the aerospace, defense and high-performance (ADHP) electronics sectors have been reluctant to migrate to lead-free because there is not enough data on the reliability of lead-free components in such applications. The lead-free gap between commercial and defense electronics will only grow as lead-free becomes more entrenched in cutting-edge commercial technologies, and as governments – especially the European Commission – seek even more stringent rules on the use of lead. IPC believes a five-year, $40 million investment in a public-private R&D program would yield more than $100 million in U.S. defense savings per year and improve military readiness and overall innovation. 
Together with our partners in the Pb-Free Electronics Risk Management (PERM) Council, comprised of experts from government, industry, academia, and other stakeholders, IPC will continue to advocate for a robust, long-term approach to this issue. Read our April 2019 blog for even more background, and watch this space and IPC.org for updates.
Lead-free materials are widely used commercially, but defense and aerospace programs lack sufficient reliability data for mission-critical uses. Funding supports research needed to ensure lead-free components can perform safely and consistently in high-stress defense environments.
These sectors rely on proven reliability, yet there is limited data on how lead-free components behave under demanding conditions. As commercial technologies move further into lead-free manufacturing, the performance gap between commercial and defense electronics continues to widen.
The funding serves as seed money for a broader R&D initiative aimed at understanding and mitigating risks associated with lead-free electronics in mission-critical systems. It supports early research that could eventually lead to large-scale testing and standards development.
IPC estimates that a sustained five-year, $40 million program could save the U.S. more than $100 million annually by improving readiness and reducing failures. Long-term investment is needed to address risks, modernize defense systems, and keep pace with commercial innovation.
The PERM Council brings together experts from government, industry, and academia to guide research priorities, assess risks, and advocate for coordinated approaches. Their work helps ensure that R&D efforts address real-world challenges across the defense electronics ecosystem.