All Case StudiesAerospace
Aerospace Power Controller
Power
50kW
Result
DO-160G certified
Industry
Aerospace
OF
The Challenge
An aerospace systems integrator needed a 50kW power controller for a next-generation aircraft electrical system. The unit had to meet DO-160G environmental qualification while operating in unpressurized bays with ambient temperatures ranging from -55°C to +85°C. Weight was critical—every kilogram saved translated to significant fuel cost reductions over the aircraft's lifetime. The design also required fault-tolerant architecture with redundant power paths.
Our Approach
- Conducted detailed thermal analysis for extreme temperature cycling conditions
- Designed lightweight aluminum-alloy cold plate with optimized flow channels
- Selected aerospace-grade components with extended temperature ratings
- Implemented redundant cooling paths for fault-tolerant operation
- Performed vibration and shock analysis per DO-160G requirements
- Validated design through altitude chamber and thermal cycling tests
Results
DO-160G
Certification
Full environmental qualification achieved
12.5 kg
Weight
40% lighter than previous generation
-55 to +85°C
Temp Range
Full power across range