Ruggedized Custom Military Power Supplies & COTS Power Converters
Wall Industries designs, verifies, and manufactures custom military power supplies, modified commercial-off-the-shelf (COTS) units, and ruggedized DC/DC converters built to operate flawlessly in extreme environments. Engineered to meet demanding defense specifications, our military power conversion solutions ensure uninterrupted performance across airborne, shipboard, ground mobile, and tactical deployment applications.
With over 60 years of power design expertise in North America, our engineering team works directly with global prime contractors, system integrators, and OEM engineering departments. We help defense equipment manufacturers overcome technical bottlenecks related to input transients, tight enclosure volumes, electromagnetic interference (EMI), harsh thermal operating limits (-55°C to +125°C), high shock, and intense mechanical vibration.
Wide Thermal Range Capabilities
-55°C to +125°C operational capabilities with conduction baseplate cooling, conformal coating, or full potting options.
High-Density & VITA Standards
Compact form factors including VPX, VME, full brick, half brick, quarter brick, and customized low-profile military enclosures.
Transient & EMI Suppression
Integrated military-grade EMI filters and surge protection handling severe voltage spikes and cranking disturbances.
Nuclear Event & Fault Protection
Select defense architectures incorporate Nuclear Event Detection (NED) auto-shutdown and restart functionality.
Military Standard Compliance Capabilities
Our custom military power supply designs and screening processes are aligned with critical defense standards. Every custom unit undergoes design verification, stress screening, and rigorous test protocols tailored to your exact military project specification:
Core Military Power Conversion Technologies
1. Military ATX Style & Modular Converters
Modern military computing architectures demand ruggedized DC/DC converters capable of supplying stable, multi-rail power to defense computers under extreme battlefield stress. Wall Industries manufactures military ATX style converters in VME, VPX/VITA, and custom enclosed form factors. Equipped with internal EMI suppression and optional Nuclear Event Detection (NED) circuits, these power supplies shield sensitive digital processors during tactical operations.
2. Ruggedized DC/DC Power Converters (1W to 7kW+)
Our isolated and non-isolated DC/DC converters support 2:1 and 4:1 wide input ranges, high electrical efficiency up to 93%, and multi-output capabilities. Designed for high power density applications, features include continuous short-circuit protection, remote sense, external voltage trim, remote on/off control, and power sequencing across custom brick topologies.
3. High-Reliability Military AC/DC Power Supplies (1W to 3kW+)
Offered in open-card, cased chassis-mount, and fully potted configurations, our AC/DC defense power systems convert single-phase or three-phase utility and generator power into tightly regulated DC rails. Equipped with active power factor correction (PFC) and soft-start circuitry, these units maintain reliability under fluctuating source conditions.
Proven Defense Custom Engineering Case Projects
Wall Industries has a proven track record of solving tough electrical and environmental challenges for global defense OEM clients. Below are real-world case applications where our engineering team delivered purpose-built power hardware:
7kW Liquid-Cooled Military Ground Vehicle Converter
Engineered a watertight 350VDC to 28VDC liquid-cooled power conversion system for tactical vehicles operating in high-vibration zones. The design integrated dual outputs (28VDC at 200A continuous and 14VDC at 100A continuous) with a custom cold-plate interface directly utilizing the vehicle radiator fluid.
Armored Multi-Purpose Vehicle (AMPV) Intelligent Power System
Developed two custom line-replaceable unit (LRU) DC/DC power converters for next-generation armored brigade combat vehicles. Feature sets included a 13-output isolated LRU complying with MIL-STD-1275 D initial cranking disturbance, ATPD-2407, MIL-STD-461, and MIL-STD-810G alongside continuous system telemetry feedback.
Ground Vehicle Tactical GPS Power Supplies
Designed compact, continuous-current mode power supplies for military wheeled and tracked vehicle navigation units. Engineered for minimal spatial footprint and low EMI profile to prevent signal interference with defense communications and targeting systems.
Digital Vehicle Distribution Box (DVDB) Multi-Output Units
Created three custom multi-output power units featuring up to 13 discrete isolated output channels for vehicle hull diagnostics, power distribution, and driver video management systems. Fully qualified for military shock, vibration, and EMC requirements.
Maritime & Submarine Self-Powered Navigation Systems
Customized ultra-compact power units designed for harsh marine deployment. Ruggedized housing withstands severe thermal cycles, salt air immersion, and shock dynamics in propulsion, autonomous sub-surface systems, and shipboard launch controls.