Aerospace-grade sensor replacement method

A method for installing a replacement electrical heat sensor in a heatable aircraft window laminate structure comprising the steps of:

• heating the aircraft window laminate structure;
• photographing the aircraft window laminate structure using an infrared camera to determine uniformity of heat distribution;
• installing a replacement electrical heat sensor in the aircraft window laminate structure if there is a lack of uniformity of heat distribution;
• the steps of installing the replacement electrical heat sensor including:
• drilling a blind hole in an edge of the aircraft window laminate structure;
• routing a channel in the edge of the aircraft window laminate structure from the blind hole to a terminal block of an originally installed heat sensor;
• inserting the replacement heat sensor into the hole;
• and
• filling the hole with a material to seal the hole and the replacement heat sensor from exposure to moisture and contamination.