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AirBorn VPX 3U and 6U power supplies.

AirBorn Custom Power Supplies

Supporting a variety of application-specific embedded systems, AirBorn Custom Power Supplies deliver durable and reliable power for aerospace, defense and space applications subject to extreme temperatures, high altitudes, severe shock and high vibration. A collaborative development approach and a wide range of available options help optimize performance, streamline integration, ensure compliance and shorten development timelines.

Features and Benefits


Embedded systems subject to harsh conditions such as extreme temperatures, shock, vibration and altitude require robust and high-reliability power supplies. These power supplies must comply with industry or regulatory standards, meet application-specific requirements for power input and output, and integrate seamlessly with controllers and external systems. To optimize program efficiencies, power supplies must also support streamlined design, prototyping, qualification and production processes.

AirBorn Custom Power Supplies are engineered to solve formidable power management challenges in aerospace, defense and space systems. These embedded or stand-alone power solutions are designed to withstand extreme conditions, providing ultra-reliable performance despite wide temperature ranges, high altitudes, severe shocks and high vibration. A collaborative approach provides end-to-end support and expertise, from initial concept through design, prototyping, testing and qualification. AirBorn Custom Power Supplies meet stringent aerospace standards and streamline system integration by offering various customizable firmware, sensor, pin-definition and communication-protocol options. Vertically integrated manufacturing and 100% factory environmental stress testing ensure quality, durability and rapid deployment for essential power systems. Efficient and compact designs also enable retrofits that deliver more power in the same footprint for system upgrades.

Custom, Collaborative Design Process

End-to-end engineering support augments the customer’s design team, helping optimize the entire system for reliability, thermal management and performance while streamlining development cycles, reducing risk and accelerating time to market.

Aircraft mechanics and engineers in the hangar.

Embedded Intelligence and Advanced Monitoring

In-house firmware development supports integration and communication with controllers and external systems via active fault and status logging, field-upgradable firmware and real-time system monitoring. These capabilities enhance reliability, facilitate predictive maintenance and support advanced control strategies.

Computer circuit board closeup.

Ruggedized, High-Reliability Performance

AirBorn Custom Power Supplies meet stringent shock, vibration, temperature and environmental standards, offering high power density, low noise and efficient thermal management options for essential applications requiring exceptional reliability.

AirBorn Custom Power Supply.

Meets unique system architecture and interface requirements
Adaptable configurations and flexible input/output (I/O) and pin definitions help minimize design challenges for complex systems.

Enables seamless integration with a diverse array of electronics
Support is available for multiple protocols, including Ethernet, CAN, SPI and I2C, streamlining system integration and shortening time to market.

Supports low- and high-power requirements
Designs are available for 30 to 300,000W, offering power solutions for a wide variety of embedded systems.

Minimizes space requirements
With up to 50% greater efficiency and an 80% smaller footprint compared to legacy linear power supplies, these precision power solutions offer drop-in retrofit and upgrade capability for space- and weight-constrained systems.

Ensures quality from prototype to production
Vertically integrated manufacturing and qualification offers an efficient design and manufacturing process, reduces costs and accelerates lead times.

Accelerates development time with a collaborative engineering process
Direct access to in-house field support and engineering expertise helps optimize designs and streamline troubleshooting.

Complies with global standards
Power supplies are available that reduce validation and compliance requirements by meeting standards such as MIL-STD-461, -704, -810, -1275 and -1399; MIL-DTL-901; RTCA DO-160; EN2282; DEF Stan 61-5; and more.

Datasheets and Guides


Applications by Industry


Avionics
Commercial aircraft
Unmanned aerial vehicles (UAVs)

Ground vehicles
Military jets
Submarines

This is not a definitive list of applications for this product. It represents some of the more common uses.

Frequently Asked Questions


What are AirBorn Custom Power Supplies?

AirBorn Custom Power Supplies are custom-engineered power supply solutions, available as stand-alone or embedded systems and designed to meet specific customer requirements for efficiency, regulatory compliance and reliability in demanding environments.

What customization options are available?

Customization capabilities include firmware, embedded sensors, thermal management, pin definitions, I/O options, communication protocols, mechanical packaging and power ratings.

What standards can these power supplies meet?

Solutions are available that are ANSI/VITA-compliant and meet MIL-STD-461, MIL-STD-704, MIL-STD-810, MIL-STD-1275, MIL-STD-1399, MIL-DTL-901, RTCA DO-160, EN2282, DEF Stan 61-5 and more.

What industries use AirBorn Custom Power Supplies?

These power supplies are ideal for the aerospace, defense, robotics and space industries.

Can Molex support retrofit/replacement projects?

Yes, drop-in replacement options are available for legacy power supplies, offering up to 50% improvements in efficiency and a footprint up to 80% smaller.

What is the typical power output range?

Solutions are available for 30 to 300,000W, making AirBorn Custom Power Supplies suitable for a wide range of low- to high-demand applications.

What cooling methods are supported?

Conduction, convection and liquid cooling—either polyalphaolefin (PAO) or ethylene glycol (EGW)—are available, with robust engineering support to ensure designs are thermodynamically optimized.

Are these products tested for environmental reliability?

AirBorn Custom Power Supplies undergo 100% factory environmental stress screening (ESS) testing and qualification, including testing for operation in -55 to +105°C temperatures and in high-shock, -vibration and -altitude conditions.

What communication protocols are supported?

These power supplies support Ethernet, CAN, SPI, I2C and other protocols, adapting to application-specific systems and integration needs.

What support is available after installation?

With in-house factory and field support expertise, Molex offers ongoing engineering assistance for troubleshooting and performance optimization.

Can Molex help with a power supply that has already been designed?

Yes, Molex can work collaboratively with customers to help take an existing design through testing, qualification and mass production.