Power Conversion Engineering
UL/EN 60601-1 certified AC/DC power supplies and high-isolation DC/DC converters engineered for patient care, diagnostic systems, and surgical equipment.
In medical environments, power system failure is not an option. Wall Industries designs, verifies, and manufactures high-reliability AC/DC power supplies and DC/DC converters engineered specifically for critical healthcare applications—including operating rooms, intensive care units, medical imaging systems, and ambulatory field medical equipment.
Our engineering team possesses deep expertise in designing to stringent international safety standards such as UL 60601-1, EN 60601-1, and IEC 60601-1 (3rd & 4th edition). Whether your design requires strict 2MOPP (Two Means of Patient Protection) isolation, micro-amp leakage currents, zero-noise medical EMI compliance, or custom form factors, we deliver fully customized power architectures tailored to your end-system requirements.
From ultra-compact PCB-mount modules to high-power enclosed system supplies with battery management, our design capabilities cover the full spectrum of healthcare applications.
Power ranging from 1W to 7kW+. Features 2:1 and 4:1 wide input ranges, high efficiencies up to 93%, high isolation up to 8kVDC, remote sense, external trim, continuous short-circuit protection, and compact brick footprints (1/8, 1/4, 1/2, and full brick).
Power ranging from 1W to 3kW+. Available in open frame, U-frame, fan-cooled enclosed, and encapsulated mechanical designs. Standard features include universal AC input (85–264VAC), soft start, active PFC, and low leakage current engineered for patient-connected equipment.
Custom microchip-controlled medical UPS designs providing uninterrupted power transition, integrated battery charging, telemetry monitoring, and fault-free operation during AC mains loss for critical surgical and life-sustaining equipment.
Explore how our US power design team solved severe mechanical, thermal, and electrical safety challenges for leading global healthcare equipment OEMs.
Challenge: A medical OEM needed a cost-optimized, ultra-reliable medical-grade power supply for home-care CPAP breathing assistance machines with strict derating and offshore volume production needs.
Solution: Wall Industries modified an existing medical-grade AC/DC platform to meet strict derating guidelines and performance screening, delivering a high-volume, cost-conscious power module within the client's critical time-to-market window.
Challenge: A military medical equipment manufacturer required a ruggedized DC/DC power converter to charge defibrillator batteries directly from airborne or ground vehicle DC power buses.
Solution: Engineers developed a wide input range dual-compliant power converter meeting EN60601-1 (3rd edition) medical safety alongside MIL-STD-810 shock/vibration and MIL-STD-461 EMI specifications.
Challenge: A leading surgical robotics manufacturer required a high-reliability internal power supply with integrated battery backup capability to prevent power interruption during critical surgical procedures.
Solution: Wall designed a Microchip-based EN60601-1 certified medical power supply with active battery management, enabling continuous trickle charging during normal operation and seamless power transition during utility grid outage.
Healthcare equipment demands zero failure. Every power supply engineered in our Exeter, NH facility undergoes robust screening protocols to guarantee safety and compliance before system installation.
Every single medical power unit undergoes 100% thermal burn-in testing under full load to eliminate early-life component failures and verify thermal performance before customer delivery.
Precision topology design and shielding ensure patient and ground leakage currents strictly adhere to 2MOPP limits for body-floating (BF) and cardiac-floating (CF) medical equipment requirements.
We support long-term OEM medical product lifecycles (10–20+ years). We maintain component traceability, offer legacy replacement engineering, and protect your bill-of-materials from obsolescence.
Our medical custom power solutions are designed, tested, and certified to meet international medical safety standards including UL 60601-1, EN 60601-1, and IEC 60601-1 3rd and 4th edition standards, supporting both Means of Patient Protection (2xMOPP) and Means of Operator Protection (2xMOOP).
Yes. We engineer integrated uninterruptible power supply (UPS) capabilities into custom medical power modules, such as Microchip-based smart battery management for surgical robotics and life-support devices ensuring zero interruption during AC line dropouts.
Every custom medical unit undergoes 100% burn-in testing under full electrical load, dielectric high-pot isolation testing, thermal cycling, and leakage current verification to guarantee patient safety and zero-defect operation in operating rooms and clinical settings.
A modified standard takes a proven, certified medical base platform and modifies output voltage, wiring harnesses, mechanical enclosures, or thermal derating—saving time and certification costs. Fully custom designs start from a blank sheet to fulfill non-standard footprints, multiple specialized rails, and complex mechanical envelopes.
Partner with our Exeter, New Hampshire engineering team to design, qualify, and manufacture custom UL/EN 60601-1 compliant power supplies for your next medical device project.