On Board Charger For Aerospace Industry Applications

Aerospace OBC Series

On Board Chargers for Aerospace Applications

Precision-engineered on board chargers designed for unmanned drones, electric aircraft, and aerospace power management systems — delivering reliability where it matters most.

AC DC 24V 3.3kW On Board Charger for Aerospace UAV

OBC Charger for Unmanned Aerial Systems

High-Efficiency On Board Charger for eVTOL Aircraft

Aerospace-Grade On Board Battery Charger Module

2011

Established In

14+

Years R&D Experience

1300+

Product Models

2–3

New Models Every Month

Industry Insights

On Board Chargers in the Aerospace Industry: Market Status & Emerging Trends

🚀The Rise of Electric Propulsion in Aerospace

The global aerospace industry is undergoing a profound electrification revolution. Driven by the rapid expansion of unmanned aerial vehicles (UAVs), electric vertical takeoff and landing (eVTOL) aircraft, hybrid-electric regional jets, and next-generation satellite platforms, the demand for high-performance on board chargers (OBCs) has never been greater. According to industry analysts, the global electric aviation market is projected to surpass USD 27 billion by 2030, with on board power management systems — including OBCs — representing one of the fastest-growing subsegments.

Unlike conventional automotive OBCs, aerospace-grade on board chargers must satisfy a far more demanding set of requirements: extreme temperature resilience (from -55°C to +125°C), high altitude derating, vibration and shock resistance, stringent EMI/EMC compliance, and ultra-high power density. These constraints drive manufacturers toward advanced wide-bandgap semiconductor topologies (GaN and SiC), digital control architectures, and highly integrated multi-function power modules.

⚡ Key Market Driver: The commercial drone delivery market alone is expected to deploy over 1 million electric UAVs globally by 2027, each requiring a reliable, lightweight on board charging solution.

📡Commercial & Industrial Market Status

Today, on board chargers for aerospace applications serve a diverse and rapidly growing commercial ecosystem:

Commercial UAV & Drone Logistics: Companies like Amazon Prime Air, Wing, and DHL are deploying electric delivery drones at scale. Each drone requires a compact, high-efficiency OBC capable of fast-charging lithium-polymer or lithium-ion battery packs between missions — often within 15–30 minutes to maintain operational throughput.
eVTOL Urban Air Mobility (UAM): Startups and OEMs developing air taxis (e.g., Joby Aviation, Archer, Lilium) are integrating multi-kilowatt OBCs directly into the aircraft's power distribution architecture. These systems must charge high-voltage battery packs (400V–800V) while complying with DO-160G environmental testing standards.
Military & Defense UAVs: Defense agencies worldwide are investing heavily in autonomous aerial platforms. Military-grade OBCs must meet MIL-STD-461 for EMI and MIL-STD-810 for environmental durability, while maintaining secure, interference-resistant operation in contested electromagnetic environments.
Satellite & Space Systems: Low Earth Orbit (LEO) satellite constellations (e.g., Starlink, OneWeb) utilize on board power management systems that include battery charge regulators (BCRs) — a specialized class of OBC — to manage solar panel input and battery storage across orbital day/night cycles.
Electric Regional Aircraft: Hybrid-electric commuter aircraft programs require high-power OBCs (10kW–100kW+) capable of operating from ground power units during turnaround, with seamless integration into the aircraft's electrical power system (EPS).

📈Technology Trends Shaping Aerospace OBCs

The aerospace OBC landscape is being reshaped by several converging technology trends that demand close attention from procurement engineers and system integrators:

Wide-Bandgap Semiconductors (GaN & SiC): Silicon Carbide (SiC) MOSFETs and Gallium Nitride (GaN) transistors enable switching frequencies above 100kHz, dramatically reducing passive component size and improving efficiency to 97%+ — critical for weight-sensitive aerospace platforms.
Bidirectional OBC Architecture: Next-generation aerospace OBCs support bidirectional power flow, enabling vehicle-to-grid (V2G) or vehicle-to-infrastructure (V2X) energy transfer, as well as regenerative energy recovery during descent or braking phases.
Integrated Multi-Port Power Management: Modern aerospace power systems consolidate the OBC, DC-DC converter, and power distribution unit (PDU) into a single, highly integrated module — reducing weight, volume, and wiring complexity.
Digital Twin & Predictive Monitoring: AI-driven battery management systems (BMS) paired with smart OBCs use real-time telemetry and machine learning algorithms to optimize charge profiles, predict battery degradation, and prevent thermal runaway events.
Wireless Power Transfer (WPT): Emerging inductive and resonant wireless charging pads are being developed for autonomous drone recharging stations, enabling fully hands-free, continuous operations without physical connector wear.

🔬Deep-Dive: Application Scenarios for Aerospace OBCs

Scenario 1 — Autonomous Drone Delivery Hub: A logistics operator running 50 delivery drones from a single hub requires a fleet-level charging infrastructure. Each drone's on board charger (typically 1.5kW–6.6kW) must accept AC input from a standard ground power outlet, convert it to the precise DC voltage and current profile demanded by the battery pack, and communicate charge status via CAN bus or SMBus to the fleet management system. Huyssen Power's compact, high-density OBC modules are engineered for exactly this scenario — delivering fast, reliable charging in a form factor optimized for airborne weight constraints.

Scenario 2 — eVTOL Air Taxi Turnaround: An air taxi operator needs to turnaround a 5-seat eVTOL in under 8 minutes at a vertiport. The on board charger must accept 400V three-phase AC from a dedicated vertiport charging post and deliver 100kW+ to the high-voltage battery pack. This demands OBC designs with advanced thermal management, active power factor correction (PFC), and galvanic isolation rated to aerospace safety standards (DO-254, ARP4754A).

Scenario 3 — Military Reconnaissance UAV Forward Operating Base: In a field-deployed military scenario, a tactical UAV must be recharged from a portable generator or vehicle power outlet within 20 minutes. The OBC must tolerate wide input voltage variation (85V–265V AC), operate reliably from -40°C to +85°C, and produce zero conducted emissions that could compromise the unit's electromagnetic silence. Custom ruggedized OBC modules with conformal coating and hermetic sealing are essential.

Scenario 4 — Hybrid-Electric Regional Aircraft Ground Servicing: During gate turnaround, a 19-seat hybrid-electric commuter aircraft connects to a 50Hz or 400Hz ground power unit. The aircraft's on board charger must intelligently manage the transition from flight mode (generator-powered) to ground charging mode, balancing battery state-of-charge across multiple battery strings while communicating with the aircraft's central maintenance computer (CMC).

Future Outlook

Key Technology Trends in Aerospace On Board Charging

⚙️

SiC & GaN Power Devices

Wide-bandgap semiconductors push switching efficiency beyond 97%, enabling ultra-compact OBC designs that meet the strict weight budgets of aerospace platforms without sacrificing power output.

🔄

Bidirectional Power Flow

Advanced OBCs support two-way energy transfer — charging the battery from ground infrastructure while also enabling energy recovery and grid support, unlocking new operational economics for electric aviation.

🤖

AI-Driven Smart Charging

Machine learning algorithms integrated with BMS and OBC firmware dynamically adapt charge profiles to battery health, temperature, and mission requirements — maximizing cycle life and safety margins.

📶

Wireless Charging for Drones

Resonant inductive charging pads enable fully autonomous drone recharging at unmanned stations, eliminating connector wear and enabling 24/7 continuous aerial operations for surveillance and logistics.

🛡️

DO-160G & MIL-STD Compliance

Aerospace OBCs must pass rigorous environmental qualification including vibration, thermal shock, altitude, and EMI testing — ensuring zero-failure performance across the full aircraft service life.

🔗

Integrated Power Architecture

Consolidating OBC, DC-DC converter, and PDU into a single module reduces system weight and wiring complexity — a critical advantage for every kilogram saved in aerospace design.

Application

Application Areas

Unmanned Drone

Aerospace

Automotive Electronics

Electrolytic Hydrogen Production

IC Semiconductors

LED Grow Light

LED Lighting

Medical Equipment

About

Company Profile

Established in 2011, Huyssen Power is committed to being a better provider of power solutions. Our production lines include AC-DC power supplies, Din Rail power supply, Programmable power supply, Battery chargers, DC-DC converters, and aerospace-grade on board chargers.

We have more than 1300+ models, widely used in various fields such as industry, Aeronautics and Astronautics, communication, healthcare, EV cars, consumer electronics, LED lightings, and more. With 14+ years of R&D experience, we deliver mission-critical power solutions for the most demanding aerospace applications.

Our Strengths

Quality Assurance & Design Service

Quality Assurance (QA)

All of our products are engineered to meet worldwide safety standards. Quality and process control is insured using a variety of statistical sampling and analysis techniques throughout the manufacturing cycle. In addition, all products should pass a rigorous burn-in and fully automated final test before shipment. We have two production bases, one is in Shenzhen and the other is in Dongguan, with timely delivery.

Design Service

Furthermore, Huyssen Power also offers the design service in order to meet customers' special requirements. If you can't find a suitable model from our catalog, our experienced R&D team can design a custom-made power supply to meet your needs. With over 22 years of R&D design experience in the power supply industry, we offer a total solution for you and would like to become your long-term power partner.

Customization

Customization Process

Customization process of aerospace on board charger power supply:

01

Requirements Communication

02

On-demand Design

03

Confirm Design

04

Product Sampling

05

Product Validation

06

Mass Production

07

Quality Inspection

08

Deliver to Customer

OEM/ODM

One Stop OEM/ODM Solution for Aerospace Power Supply

Huyssen Power, with years of power supply experience and advanced production technology, is committed to providing global customers with one-stop OEM/ODM services from product design, research and development, production to delivery, helping you easily expand your market and solve your personalized product needs.

🛠️ ODM Service

If you are interested in developing new products and want to create your own aerospace power supplies, we provide a one-stop solution from product concept, design, research and development to production.

Product development and production — A professional power supplies development team transforms concepts into testable prototypes.
Large scale production line — Our own factory supports the large-scale production of power products.
Testing and Certification Support — Assist power products in passing various international standards and certifications.

🏭 OEM Services

If you have mature product designs, technical specifications, or existing samples, that's great. We can provide efficient and high-quality OEM production services.

Precise production — Strictly follow your drawings and quality standards for production.
Cost optimization — With large-scale procurement and lean production, we can reduce production costs for you.
Quality assurance — A strict quality control system ensures that every product meets your standards.
Capacity support — Flexible production capacity to meet the needs of small-scale to large-scale production.
Confidentiality Agreement — Strictly abide by the commercial confidentiality agreement to protect your intellectual property rights.