Power Conversion Engineering
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Power Conversion Engineering
Purpose-built AC/DC power supplies and DC/DC converters engineered from the ground up or modified from proven platforms to satisfy your precise OEM electrical, thermal, and regulatory requirements.
When off-the-shelf catalog power supplies cannot fulfill your unique physical dimensions, voltage rails, ambient thermal parameters, or stringent safety certifications, Wall Industries, Inc. delivers tailored engineering solutions. Backed by over six decades of power design leadership in New Hampshire, USA, our engineering team works directly with global OEM product design teams to solve complex power conversion challenges.
Whether your application requires a minor modification to an existing standard platform—such as custom harness pinouts, conformal coating, or tuned output voltage trims—or a completely custom ground-up design, our electrical and mechanical engineers utilize industry-proven topologies (LLC resonant, active PFC, flyback, forward, buck/boost) to minimize development risk and accelerate time-to-market.
We combine collaborative architecture reviews with rigorous testing procedures to guarantee optimal electrical performance and long-term reliability for demanding industrial and defense applications.
Our power design engineers conduct an in-depth review of your technical specification, evaluating voltage inputs, transient loads, isolation, cooling strategy, mechanical envelope, and target compliance standards.
We select qualified topologies and high-reliability magnetic design to model electrical performance, thermal distribution, and EMI emissions before hardware layout approval.
Rapid engineering prototypes are produced and subjected to thorough Design Verification Testing (DVT), including thermal imaging, transient load profiling, and preliminary pre-compliance screening.
Following final design sign-off, full OEM production takes place with comprehensive burn-in procedures, automated testing, and total lifecycle management for up to 15+ years of continuous service.
Specialized design tracks tailored to the environmental, safety, and operational demands of mission-critical global equipment.
Engineered for combat vehicles, airborne radar, shipboard systems, and tactical communication gear operating under harsh shock, vibration, and extreme temperature ranges.
Custom patient-proximity power conversion solutions built to meet strict medical safety directives and ultra-low leakage current requirements.
Ruggedized power designs intended for continuous high-duty industrial controls, automated robotics, smart grid hardware, and outdoor infrastructure.
An indicative range of electrical parameters and physical options available for modified and fully custom power development projects.
| Parameter | AC/DC Custom Capabilities | DC/DC Custom Capabilities |
|---|---|---|
| Power Output Range | 1 Watt up to 3,600 Watts | 0.5 Watts up to 1,500 Watts |
| Input Ranges | Universal 85–264 VAC, 90–305 VAC, 3-Phase 480 VAC | 5 V, 12 V, 24 V, 48 V, 110 V, 310 VDC; 2:1 and 4:1 wide input |
| Output Configuration | Single, Dual, Triple, Quad; 1.2 V to 500 VDC high-voltage rails | Single, Dual, Triple; regulated or unregulated isolation |
| Isolation Ratings | Up to 4,000 VAC (2×MOPP reinforced) | 1,500 VDC up to 8,000 VDC high isolation options |
| Thermal Management | Conduction baseplate, forced air, open frame, cold plate | Encapsulated potting, baseplate cooling, heatsink accessories |
| Operating Temperature | -40°C to +85°C standard; extended -55°C to +125°C on request | -40°C to +85°C standard; extended -55°C to +125°C on request |
Initial engineering consultation and specification analysis take 1 to 2 weeks. Modified-standard designs generally yield prototype samples within 4 to 8 weeks, while full ground-up custom designs typically require 12 to 16 weeks for prototype verification depending on component selection and compliance scope.
A modified-standard design starts from an established, field-proven catalog platform and modifies specific features (such as harness length, output voltage trim, potting material, or connector types). This path minimizes tooling costs and safety re-certification time. A fully custom design is recommended when strict mechanical envelopes, unusual multi-rail requirements, or specialized military standards require a unique architecture.
Our designs are engineered from inception to satisfy targeted standards such as UL/EN 60601-1 for medical gear, EN 50155 for transit, and MIL-STD-461 for electromagnetic compatibility. We perform pre-compliance screening in-house and provide complete design documentation to assist your team during final agency approval.
Yes. We routinely design custom power supplies operating in extreme environments ranging from -55°C to +125°C, featuring conduction-cooled baseplates, silicone/epoxy potting for potting immersion, conformal coatings for high humidity, and ruggedized packaging resistant to high shock and vibration.
Connect directly with our engineering team in Exeter, New Hampshire to evaluate your specification, select optimal design topologies, or request a custom technical proposal.
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