Custom Power Solutions


Astronics provides turn-key design and manufacturing of custom high performance rugged power supplies and power management products for the military and aerospace markets.

Product Info

For nearly six decades, Astronics has been providing power supply and power management products for commercial, business, helicopter, military, and missile systems with over 345,000 power units delivered.

Astronics’ Custom Power Solutions are Designed, Qualified, and Built to customer specifications, and cover a full range of power levels from 5W to over 10kW for all types of converters and inverters where tight tolerances and reliability in severe environments are key. Power supplies and converters developed by Astronics utilize state of the art technologies to increase reliability while lowering weight, volume, and cost.  Astronics’ design capabilities for hardware and software extend to critical flight systems where compliance to Design Assurance Level (DAL) Level A (Catastrophic) is required.

Dual Power Distribution Unit Seat Power Box (SPB)Power Distribution Unit


  Regulated Power Conversion Unit (RPCU)Power Conversion Unit (PCU)

Astronics ensures compliance with all industrial, regulatory, OEM, and military requirements using in-house testing and integration capabilities augmented with established relationships with several certified testing facilities.  Highly Accelerated Life Test (HALT) is available as part of the design process for all electrical and mechanical designs. Astronics also maintains a fully equipped and conformable Systems Integration Lab (SIL) to test and integrate systems in an “aircraft” environment to validate functionality and interoperability with other systems early in the design process.   

HALT Chamber and Systems Integration Lab (SIL)

The Company is a "Final Assembly and Test" facility employing modern industry accepted manufacturing practices operating under AS9100 and ISO 9001 certifications. Manufacturing lines are designed using Lean Enterprise concepts and tools such as “Kaizen”, “5S”, “DFM” (Design For Manufacturability), and kanban replenishment systems for materials. The use of metrics to drive continuous improvement throughout the manufacturing operation is standard.

Core manufacturing capabilities include:

  • Electrical and Mechanical assembly
  • Conformal coating
  • HASS (Highly Accelerated Stress Screening)
  • ESS (Environmental Stress Screening)
  • Functional and Acceptance testing (FTP and ATP)
  • ESD (Electrostatic Discharge) control and testing
  • FOD (Foreign Object Debris) control and training
  • "5S" and "Lean" Manufacturing training and application
  • “Kaizen” and “mistake-proofing” events
  • AOG support (in coordination with in-house CRR Department)

Consistently high product reliability is realized by performing Highly Accelerated Stress Screening (HASS) and/or Environmental Stress Screening (ESS). These tests accelerate burn-in testing while performing functional verification testing. These test regimens are available for all power products manufactured by Astronics.

Astronics' Lean Manufacturing and Environmental Stress Screening (ESS) 

When you have a need for a Custom Power Solution contact your Astronics Sales Representative to discuss how we can help.



Contact & Support

Astronics AES, Business Aircraft, Rotorcraft and Military

12950 Willows Road NE
Kirkland, WA 98034 USA

Contact & Support

Astronics AES, Business Aircraft, Rotorcraft and Military

12950 Willows Road NE
Kirkland, WA 98034 USA


P: +1.425.881.1700

Contact Sales