Engineered to operate without failure in extreme environments. Helios designs, manufactures, and integrates custom military power conversion, rugged DC UPS, tactical chargers, and power distribution systems.
Defence power engineering requires a fundamental shift from commercial standards. In modern tactical deployment, land-mobile operations, and naval C4ISR command nodes, power systems are subjected to severe mechanical shock, ballistic vibration, wide ambient temperature swings (-40°C to +70°C), and aggressive electromagnetic interference. Standard commercial supplies fail under these conditions due to component stress, thermal throttling, or high conducted emissions.
Global procurement teams and defence integrators face complex decisions when balancing **COTS (Commercial Off-The-Shelf)** flexibility against strict **MIL-STD compliance** (MIL-STD-810H, MIL-STD-461G, MIL-STD-1275E, and STANAG standards). A single power architecture oversight can lead to system resets during engine cranking, electromagnetic detection by enemy signals intelligence, or catastrophic thermal failure in unconditioned tactical shelters.
At **Helios Power Solutions**, backed by over **38 years of power conversion expertise** and an **ISO 9001:2015 certified design framework**, we engineer high-density, ruggedised Defence Power Supply Systems that bridge the gap between custom military specifications and modular deployment speed.
This technical guide addresses the core questions defence procurement officers, systems integrators, and field engineers ask when specifying power infrastructure for mission-critical applications:
Defence assets operate on extended service lifecycles where component obsolescence presents a significant threat to operational readiness. Prime defence contractors standardising on Helios power solutions receive dedicated engineering support, locked bill-of-materials (BOM) control, strict configuration management, form-fit-function drop-in replacements, and long-term spares provisioning. Our four regional support hubs (Australia, New Zealand, Singapore, Dubai) ensure rapid technical response anywhere in the field.
Contact Us for Programme DetailsFrom ultra-compact 1U rackmount distribution units to high-power 3-phase tactical field chargers, our field-tested portfolio represents the pinnacle of high-reliability defence engineering.
Designed specifically for compact C4ISR rack assemblies, the AMP-K5896 delivers 700W of regulated multi-channel DC power from an AC input. Featuring extreme shock isolation, internal EMI suppression filtering, and rugged MIL-DTL connectors, it is ideal for mobile command vehicles and naval combat suites.
1U Rackmount · MIL-STD-461G · Conformal Coated Contact Us
Built for tactical ground support, vehicle battery maintenance, and deployable base camps. The AMP-K5114 accepts 3-phase utility or generator input to rapid-charge 24V/48V lead-acid and LiFePO4 battery banks in high-ambient environments (+55°C without thermal shutdown).
7kW Output · 3-Phase Input · IP65 Transport Case Contact Us
Fanless operational reliability for acoustically sensitive or dirty, dust-laden environments. The Sol Series combines hot-swappable rectifier modules with smart controllers supporting DNP3, Modbus, and SNMP over secure military networks.
Fanless Convection · N+1 Redundancy · Modular Contact UsSelecting the correct power conversion topology requires evaluating environmental stress against procurement timelines and unit cost. The matrix below highlights engineering parameters for defence systems integration.
| Design Vector | Standard Industrial Power Supply | Helios MOTS (Modified Off-The-Shelf) | Helios Full Custom MIL-SPEC System |
|---|---|---|---|
| Operating Ambient | -10°C to +50°C (Standard linear derating) | -40°C to +65°C (Extended components & heatsinking) | -40°C to +71°C (MIL-STD-810H Method 501.7/502.7) |
| Vibration & Shock | Basic industrial vibration (IEC 60068) | Ruggedised chassis, internal tie-downs, conformal coating | MIL-STD-810H shock (Method 516.8) & 30g tactical drop compliance |
| EMC / EMI Profile | EN 55032 Class A/B | Enhanced internal LC filter stage for low conducted noise | MIL-STD-461G (CE102, RE102, CS114, RS103) certified filter integration |
| DC Input Transients | Nominal voltage ±15% | Wide-input range with standard TVS protection | MIL-STD-1275E (100V/50ms surge, 250V spike immunity for 28VDC) |
| Ingress & Coating | IP20 open frame / perforated cover | Humiseal 1A33 polyurethane conformal coating, IP54+ options | Fully sealed IP65/IP67 chassis or hard-anodized aluminum 19-inch rack enclosure |
| Communications | Simple volt-free relay contacts | Modbus RTU / TCP, SNMP v3, isolated dry contacts | Custom SCADA integration, DNP3 Outstation TCP, secure CANbus |
As modern battlefields transition toward electronic warfare, remote sensor networks, unmanned ground vehicles (UGVs), and high-energy directed systems, the operational demands placed on power conversion equipment are undergoing a seismic shift.
Traditional silicon-based switch-mode power supplies are reaching physical limits regarding switching frequency and thermal dissipation. Defence procurement requirements now heavily favor **Gallium Nitride (GaN)** and **Silicon Carbide (SiC)** topologies. WBG semiconductors allow power supplies to operate at significantly higher switching frequencies, reducing magnetic component volume by up to 40% while maintaining conversion efficiencies exceeding 96%. This capability enables 3kW to 5kW power delivery within ultra-compact 1U rack envelopes for tactical mobile command shelters.
Forward operating bases (FOBs) are shifting away from inefficient, continuously running diesel generators toward **tactical hybrid microgrids**. Next-generation defence power supply systems must function bi-directionally, seamlessly interfacing with solar arrays, variable-speed gensets, and advanced **Lithium Iron Phosphate (LiFePO4)** battery banks. Modern tactical power supplies act as intelligent power management nodes capable of dynamic peak-shaving, silent-watch power distribution, and automated load prioritization during combat scenarios.
With the proliferation of asymmetric electronic warfare capabilities, power supplies are increasingly vulnerable to High-Altitude Electromagnetic Pulse (HEMP) events and intentional electromagnetic interference (IEMI). Defence buyers are now mandating built-in high-attenuation matrix filtering. Through strategic engineering alignment with specialized partners such as **MPE (UK)**, Helios incorporates advanced EMP/EMI filter assemblies into custom enclosure systems to shield sensitive control electronics from catastrophic field transients.
As power conversion systems become networked via Ethernet, SNMP, or DNP3 to central battlefield management systems, they become potential entry vectors for cyber intrusions. Future procurement specs demand hardware-rooted security, encrypted firmware updates, and zero-trust protocol stacks within embedded SCADA communications controllers. Helios engineers smart controllers with isolated network channels and restricted command access to mitigate remote network manipulation.
Over 50% of shipped systems are engineered to custom military specs Off-the-shelf power supplies are built for ambient conditions controlled by commercial HVAC systems. In real-world military deployments, units are mounted directly on tactical vehicle frames, exposed to salt-spray on naval decks, or sealed in airtight cases where forced-air cooling is impossible.
Our engineering team in Australia and New Zealand specializes in solving complex electrical, mechanical, and thermal challenges:
In addition to our proprietary custom-engineered solutions, Helios integrates world-leading power components from global partners, backing every delivery with local engineering support and compliance verification.
With 38+ years of uninterrupted business, Helios has established an unassailable track record in mission-critical power system manufacturing.
Every defence power supply system undergoes fully documented end-of-line testing, high-pot isolation checks, burn-in screening, and full component batch traceability.
Our engineering labs feature programmable AC/DC load banks, EMI diagnostic receivers, surge simulators, and environmental test chambers for thorough FAT testing.
We do not just ship power supplies; we integrate complete systems—including enclosure wiring, circuit breaker distribution, battery racks, and SCADA communications.
Helios Defence Power Supply Systems undergo rigorous engineering design reviews and full environmental and electromagnetic compliance testing. We integrate shock-mounted chassis, conformal coating, custom passive/active EMI filtering, and fully sealed IP65/IP67 enclosures to survive extreme ambient temperatures (-40°C to +70°C), heavy shock, vibration, high humidity, and severe electromagnetic interference.
Contact Us to request detailed test reports and compliance certificates.
Commercial Off-The-Shelf (COTS) units offer standard features for benign environments; Modified Off-The-Shelf (MOTS) re-rates standard systems with ruggedised enclosures, specialized connectors (e.g., MIL-DTL-38999), and conformal coating for tactical duty; Custom Defence Power Systems are ground-up engineering solutions built to strict military specifications, offering precise voltage/current outputs, custom form factors (1U-4U or tactical carry cases), and custom SCADA/bus communications.
Through our Helios Priority Programme, we guarantee long lifecycle support, form-fit-function replacement options, component traceability, and proactive obsolescence notifications well beyond standard commercial product lifecycles, ensuring operational support for 15 to 25+ years.
Yes. Our DC-DC converters, rectifiers, and tactical battery chargers are designed to meet MIL-STD-1275E (for 28V DC land vehicle electrical systems) and MIL-STD-704F (for aircraft electrical power), incorporating ultra-wide input ranges, active surge suppression, and transient voltage protection against load dumps and cranking spikes.
Yes. Through our engineering partnership with MPE (UK), we integrate heavy-duty EMP, IEMI, and high-attenuation lightning protection filters directly into our power distribution systems for fixed command centers, communications shelters, and naval platforms.
Speak directly with our senior defence power engineering team today.