Open Frame Power Supply For Aerospace Industry Applications

What Is an Open Frame Power Supply in Aerospace?

An open frame power supply is a switching power supply unit without an enclosed outer casing, exposing its PCB and components for direct integration into host equipment. In the aerospace industry, this design philosophy is not merely a cost-saving measure — it is a deliberate engineering choice that enables tighter thermal management, easier inspection, reduced weight, and seamless embedding into avionics racks, satellite subsystems, and ground support equipment (GSE).

Aerospace-grade open frame power supplies are designed to withstand extreme operating conditions: wide temperature ranges (typically -40°C to +85°C or beyond), high-altitude low-pressure environments, severe vibration and shock loads, and stringent electromagnetic compatibility (EMC) requirements per DO-160 and MIL-STD-461 standards. They must also deliver exceptional efficiency — often exceeding 93% — to minimize heat generation in sealed, thermally constrained enclosures typical of aircraft and spacecraft.

The global market for aerospace power supplies has been growing steadily, driven by expanding commercial aviation fleets, the rapid proliferation of unmanned aerial vehicles (UAVs), new-generation satellite constellations (LEO/MEO), and the electrification of aircraft systems under the "More Electric Aircraft" (MEA) initiative. Open frame designs are increasingly preferred by aerospace OEMs and system integrators due to their flexibility, customizability, and superior power density.

🚀 Key Industry Insight

The global aerospace power supply market is projected to exceed USD 5.2 billion by 2030, with open frame and modular switching power supplies capturing a growing share as avionics electrification accelerates. The shift toward More Electric Aircraft (MEA) architecture is a primary catalyst, replacing hydraulic and pneumatic systems with electrically driven equivalents — all demanding robust, high-efficiency power conversion.

Market Trends Driving Aerospace Power Supply Demand

Understanding the commercial and industrial forces shaping the open frame power supply landscape in aerospace

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More Electric Aircraft (MEA) Initiative

Modern commercial aircraft such as the Boeing 787 and Airbus A350 have dramatically increased their reliance on electrical power systems. The MEA trend replaces hydraulic actuators, pneumatic bleed-air systems, and mechanical drives with electrically powered equivalents. This drives demand for high-density, high-reliability open frame switching power supplies capable of operating from 28VDC or 270VDC aircraft bus architectures.

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New Space & LEO Satellite Constellations

The proliferation of low Earth orbit (LEO) satellite constellations — including commercial broadband networks — has created unprecedented demand for compact, radiation-tolerant power conversion modules. Open frame designs allow satellite manufacturers to integrate custom power conditioning directly into structural panels, reducing harness weight and improving power distribution efficiency across payloads and bus systems.

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UAV & eVTOL Market Expansion

Unmanned aerial vehicles and electric vertical take-off and landing (eVTOL) aircraft represent the fastest-growing segment of the aerospace power supply market. These platforms demand ultra-compact, lightweight open frame power supplies with high power-to-weight ratios, wide input voltage ranges, and robust protection features. The commercial drone delivery market alone is expected to require millions of precision power conversion units annually by 2027.

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Defense Modernization Programs

Global defense spending on electronic warfare systems, radar platforms, directed energy weapons, and autonomous combat vehicles is surging. These applications demand MIL-SPEC open frame power supplies with wide input voltage tolerance, high transient immunity, and compliance with MIL-STD-704 and MIL-STD-1275. Custom open frame designs allow defense integrators to meet exacting SWaP-C (Size, Weight, Power, and Cost) requirements.

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High-Efficiency & GaN/SiC Technology

The adoption of wide-bandgap semiconductor materials — Gallium Nitride (GaN) and Silicon Carbide (SiC) — in aerospace power conversion is enabling switching frequencies above 1 MHz, dramatically reducing passive component sizes and enabling unprecedented power density. Open frame designs benefit most from these advances, as the exposed topology allows for optimized thermal management of high-frequency switching devices.

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Electrification of Ground Support Equipment

Airports and aerospace maintenance facilities worldwide are transitioning ground support equipment (GSE) — from tugs and belt loaders to preconditioned air units — to electric power. This creates a large, growing market for industrial-grade open frame switching power supplies used in battery charging systems, power distribution units, and test equipment for aircraft systems on the ground.

Deep-Dive: Aerospace Application Scenarios for Open Frame Power Supplies

From avionics to launch vehicles — where open frame power supplies are mission-critical

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Avionics & Flight Management Systems

Flight management computers, navigation systems (IRS, GPS, ADS-B), and communication transceivers require ultra-stable, low-noise DC power with tight regulation (±0.5% or better). Open frame power supplies embedded directly within avionics LRUs (Line Replaceable Units) minimize distribution losses and allow designers to optimize grounding schemes for EMI suppression. Wide operating temperature range and vibration resistance per RTCA DO-160 are mandatory requirements.

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Satellite Payload Power Conditioning

Satellite payloads — including imaging sensors, communication transponders, and scientific instruments — require isolated, regulated DC-DC power conversion from the spacecraft bus (typically 28V or 50V). Open frame power modules with radiation-hardened components (Total Ionizing Dose tolerance) and single-event effect mitigation are integrated directly into payload electronics boards, maximizing volumetric efficiency in the constrained satellite structure.

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Radar & Electronic Warfare Systems

Active electronically scanned array (AESA) radars and electronic warfare jammers demand high-power, pulsed DC supplies capable of delivering kilowatts of peak power with fast transient response. Open frame power supplies with high-voltage outputs (up to 300V+), wide bandwidth regulation, and robust EMI filtering are integrated into transmitter/receiver modules. Compliance with MIL-STD-461 CE/RE limits is essential for coexistence with sensitive receiver chains.

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Launch Vehicle & Spacecraft Bus Power

Launch vehicles and spacecraft require power distribution units (PDUs) that manage power from solar arrays or batteries to multiple subsystem loads. Open frame switching power supplies serve as the building blocks of these PDUs, providing regulated voltages for command & data handling (C&DH) systems, attitude control electronics, and propulsion control units. Redundancy, fault isolation, and telemetry reporting are key design requirements.

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UAV Autopilot & Payload Power Systems

Commercial and military UAVs integrate open frame power supplies to power autopilot computers, gimbal-stabilized cameras, synthetic aperture radar (SAR) payloads, and communication links simultaneously from a single battery bus. Designers require high efficiency (>90%) to maximize endurance, along with comprehensive protection features (OVP, OCP, OTP, SCP) to safeguard expensive payloads during dynamic flight maneuvers and power bus transients.

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Aerospace Manufacturing & Test Equipment

Aircraft component manufacturers and MRO (Maintenance, Repair & Overhaul) facilities rely on programmable open frame power supplies for automated test equipment (ATE), environmental stress screening (ESS) systems, and functional test benches. High-accuracy programmable outputs, fast settling times, and SCPI/LAN/USB interfaces enable full automation of avionics acceptance testing, reducing test cycle times and ensuring traceability to aerospace quality standards (AS9100).

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Environmental Control & Thermal Management Systems

Electric environmental control systems (ECS) in modern aircraft use variable-frequency drive (VFD) compressors and electrically driven air cycle machines. Open frame power supplies provide the precision DC power required for ECS control electronics, sensor signal conditioning, and actuator drivers. Their open construction facilitates integration with aircraft thermal management architectures, including liquid cooling plates and heat pipe assemblies.

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Ground Support Equipment (GSE) & Airport Infrastructure

Electric GSE — including aircraft towing tractors, passenger boarding bridges, pre-conditioned air (PCA) units, and GPU (Ground Power Units) — requires robust industrial open frame switching power supplies rated for continuous heavy-duty operation. High power factor correction (PFC >0.99), wide input voltage tolerance (85-264VAC), and compliance with IEC 61000 EMC standards ensure reliable operation in electrically noisy airport environments.

Critical Performance Requirements for Aerospace Open Frame Power Supplies

The technical benchmarks that define mission-ready power conversion for aerospace platforms

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Extended Temperature Range

Operational from -40°C to +85°C (or -55°C to +125°C for military grade), ensuring reliable power delivery across ground, airborne, and space environments without derating.

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High Efficiency ≥93%

Minimizes heat dissipation in thermally constrained aerospace enclosures, reducing cooling system mass and extending MTBF. Compliant with 80 PLUS Titanium and aerospace efficiency mandates.

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EMI/EMC Compliance

Meets RTCA DO-160G Category B/C conducted and radiated emissions limits, MIL-STD-461F CE102/RE102, ensuring coexistence with sensitive avionics receivers and navigation systems.

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Comprehensive Protection

Over-voltage, over-current, over-temperature, short-circuit, and reverse polarity protection with hiccup-mode or latch-off response, safeguarding high-value aerospace payloads and systems.

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Vibration & Shock Resistance

Designed to survive 20g peak shock and 5g random vibration per MIL-STD-810H and DO-160G, with conformal-coated PCBs and ruggedized component mounting for airborne applications.

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Wide Input Voltage Range

Universal AC input (85–264VAC) or wide DC input (16–160VDC) accommodating aircraft 28VDC/270VDC bus, satellite solar arrays, and ground utility power without modification.

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High Power Density

Exceeding 20W/in³ in optimized open frame designs, enabling aerospace system designers to meet stringent SWaP-C (Size, Weight, Power, Cost) budgets in weight-critical platforms.

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OEM/ODM Customization

Custom output voltages, connector configurations, mechanical form factors, conformal coating options, and screening levels (commercial, industrial, military) available to meet unique aerospace program requirements.

Company Profile

About Huyssen Power — Your Trusted Aerospace Power Supply Partner

about

COMPANY PROFILE

Huyssen Power

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 specialized open frame power supplies for demanding industrial and aerospace applications.

With over 14 years of R&D experience, more than 1,300 product models, and a dedicated engineering team continuously launching 2–3 new models every month, Huyssen Power stands at the forefront of switching power supply innovation. Our aerospace-grade open frame power supplies are trusted by system integrators across North America, Europe, and Asia-Pacific for their reliability, performance, and customization flexibility.

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2011

Established In

14+

Years R&D Experience

1300+

Product Models

2–3

New Models Every Month

Manufacturing Capabilities

World-class production infrastructure supporting aerospace-grade quality standards

Advanced Production Capabilities with Large-scale Facilities

Our factory covers an area of over 2,500 square meters and is equipped with advanced production equipment. We have three automated production lines with automated, precise, and efficient production processes.

Annual Production Capacity

The annual production capacity of switch mode power supplies can reach over 430,000 units, and there are cooperative processing plants that can cope with large-scale orders and urgent needs.

Customized Services

We focus on customer needs and provide standardized and ODM/OEM customized services to meet their diverse production needs, including aerospace-specific form factors and screening levels.

Our Equipment

We are equipped with advanced production equipment and testing instruments

Power Aging Testing Equipment

We can use it to test the stability and reliability of products such as DC power supplies and power modules under long-term and continuous load working conditions. It can also test overvoltage protection, overload protection, leakage current protection, etc., to ensure the safety of the product during the testing process. It is possible to set test parameters, control the testing process, and record and analyze test data through industrial control computers and supporting software.

Power Comprehensive Testing System

It can ensure the performance and reliability of power products under various working conditions through comprehensive performance testing, dynamic characteristic testing, protection function testing, long-term stability testing, and safety testing, thereby improving the level of quality control.

High and Low Temperature Aging Testing Equipment

It can simulate natural environmental conditions such as high temperature, low temperature, and high and low temperature cycles, and is used to test the performance and reliability of power supplies at different temperatures, ensuring that each batch of power products can meet the design requirements in terms of temperature adaptability.