Magnetic Design Labs, Inc (MDLI) supplies custom and semi-custom power conversion solutions to the military.

The company specialises in ultra-high reliability military-grade power converters using proven DSP and analogue circuitry to provide an optimal solution to your power needs. Our cutting-edge technology yields smaller, lighter, and better-performing power converters. Core products include DC-AC inverters, DC-DC converters, and AC-DC power supplies.

Power solutions built and tested to military standards

MDL’s experienced team of engineers can develop tailor-made power solutions for a wide range of military applications from 10W to 100kW. The team uses advanced circuit simulation and 3D modelling tools to eliminate problems in the design phase before the hardware is built. Prototypes and first articles are thoroughly tested to all required specifications and military standards to ensure a rugged and efficient design ahead of production.

MDL has supplied DC-DC power converters to the US military.

Our inverters and converters have been tested to 100G shock plus random vibration. They’re also tested to MIL-STD-1275 for input spikes and surges. Many of our models are additionally tested to MIL-STD-810 for temperature extremes and other environmental requirements.

MDL has expertise in both the traditional analogue technology and the newer digital (DSP) technologies. This includes a proprietary digital signal processor (DSP) based military sine wave inverter system that is parallelable. It uses our proprietary in-house C-code.

The company’s advanced design process involves reliability improvement through careful component selection, derating, in-process testing, and stringent quality control to ensure only compliant units are produced.

Power inverters for use in military vehicles and aircraft

MDL develops cutting-edge inverters for use in army tactical vehicles, aircraft, and in ground-based power applications. Both true sine wave and modified-sine wave variants are available and ruggedised models are offered specifically for military use. MDL power inverters are designed to be highly reliable and have an extremely low failure rate.

Power sizes range from 25W up to 2,500W, with some models offering up to 100kW output power. The DSP design has low output distortion of 3% typical at full output power. Standard models are available in 120VAC and 240VAC at 50Hz, 60Hz, or 400Hz output frequency and inputs of 28VDC nominal (21VDC to 32VDC).  Other voltage/frequency combinations are available upon request.

AC-DC power supplies for defence applications

MDL are specialists in both linear and switching variants of AC-DC power supplies, offering ranges from 100W to 20kW. The company supplies models in both single and multi-output configurations.

Switching power supplies are available with wide-range AC input from 85 to 265 VAC, making strapping or jumpers obsolete. Available special features include: AC power fail, DC power good, over-voltage protection, remote on/off, and output voltage margining. MDLI power supplies can be custom configured­, making them the ideal choice for any military application.

DC-DC converters for air, ground, and naval equipment

MDL has designed and developed a wide range of DC-DC converter models for the US military. Our company’s high MTBF (mean time between failure) converters have been trusted in the many critical end-item military applications where failure is not an option.

Converters are available in brick form with both potted and non-potted versions available. Single, dual (tracking and non-tracking), and multi-output variants are available. MDL converters feature optional built-in EMI filters and are designed to have a low output impedance, tight regulation, and low ripple and noise. They have been developed to be long-lasting and can withstand punishing shock and vibration.

Custom power solutions, magnetics, and battery chargers

In addition to the core range of power supplies, inverters, and converters, MDL can custom-make power solutions to meet the needs of individual clients. With a combined experience of more than 200 years, MDL engineers are capable of designing, testing, and producing power solutions to suit almost any requirement.

Military-grade battery chargers are offered by the company, with optional features such as circuit breakers and digital panel meters available on request.

The company also supplies custom-made specialty magnetics components, including high-frequency and line-frequency transformers, magnetic amplifiers, and LVDT (linear variable differential transformer) position transducers.