How do I select the right power supply for my project?

Define the input source (AC mains range or DC bus), the number and value of outputs with worst-case load and transient current, required isolation, ambient temperature and cooling method, mechanical envelope and mounting, plus the safety and EMC standards your end product must certify to. If your specification is incomplete, our applications engineers help define the requirement before design work begins.

Engineering & manufacturing in Exeter, New Hampshire, USA since 1961 [email protected]

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Wall Industries, Inc. | Exeter, NH, USA

Power Conversion Engineered in the USA Since 1961

Q: What is the difference between a modified-standard and a fully custom power supply?

A modified-standard unit starts from a proven catalog platform and changes only what your application requires — output voltage trim, connectors, cable harness, potting, coating, labelling or thermal derating. A fully custom design starts from your electrical, mechanical and compliance specification and is engineered from the ground up. Modified-standard shortens qualification time and cost; fully custom delivers exact form, fit and function.

Q: Which standards do your designs address?

Depending on the target market, our engineering team designs to requirements such as UL/IEC 60601-1 for medical equipment, MIL-STD-1275 for military vehicle power, MIL-STD-461 and CISPR/EN 55032 EMC limits, EN 50155 for rolling stock and DoE Level VI / EU CoC Tier 2 efficiency rules for external adapters.

AC/DC power supplies from 1 to 3,600 W and DC/DC converters from 1/2 to 1,500 W — standard, modified-standard and fully custom.

Explore Products Custom Solutions

60+Years in Power Design

0.5–3,600 WOutput Power Coverage

-55°C to +125°CDesign Capability on Request

Core Product Families

DC/DC Converters and AC/DC Power Supplies Built for OEM Equipment

Two complete platforms, one engineering team. Every family can be supplied as a catalog part, adapted as a modified standard, or re-engineered as a purpose-built design for your board, enclosure and compliance path.

DC/DC Power Converters

1/2 to 1,500 Watts

Isolated and non-isolated converters for distributed power architectures, wide-input transportation buses and high-isolation instrumentation.

Isolation options up to 3 kVDC – 8 kVDC for measurement and patient-connected circuits
High-voltage input models for 110 V and 310 V DC buses
Rail, vehicle and robotics platforms with wide 4:1 input windows

EncapsulatedPCB MountThrough-HoleChassis MountOpen FrameEnclosed / Ventilated

View DC/DC Series

AC/DC Power Supplies

1 to 3,600 Watts

Universal-input supplies for machinery, medical devices, lighting systems and external adapters, with efficiency levels that meet current external power rules.

Open frame, U-frame and enclosed builds for cabinet and machine integration
DIN rail models for control panels and process automation
DoE Level VI / EU CoC Tier 2 compliant desktop and wall-plug adapters

Open FrameEnclosed + FanU-FrameDIN RailDesktopWall Plug-In

View AC/DC Series

Industry Applications

Power Platforms Matched to Your Operating Environment

Shock, vibration, altitude, leakage current, EMC limits and duty cycle differ in every sector. Start from the platform already qualified for your environment.

Medical Power Supplies 2×MOPP options, low leakage current, UL/IEC 60601-1 design intent

Military & Defense MIL-STD-1275 transients, MIL-STD-461 EMI, ruggedized packaging

Railway & Transit 24/48/72/110 V nominal rail buses, wide input, EN 50155 design intent

LED Lighting Constant voltage and constant current drivers, dimming and IP builds

Industrial Automation DIN rail, PCB mount and high-temperature adapters to +70°C

Electric Vehicle Auxiliary DC/DC conversion for EV, EVSE and battery-powered platforms

Level VI External Desktop and wall-mount adapters with interchangeable plug heads

Robotics & Motion Compact converters for servo logic, sensors and cobot controllers

1961Designing Power in the USA

3,600 WMaximum AC/DC Output

8 kVDCHigh-Isolation Converter Options

6Core Industries Served

Selection Data

Compare Platforms Before You Request a Sample

A practical starting point for design engineers and sourcing teams evaluating power conversion options.

Indicative platform capability overview. Exact ratings, derating curves and approvals are listed on each product datasheet in the technical library.
Platform	Power Range	Typical Input	Isolation / Key Feature	Best Suited To
Isolated DC/DC	0.5 – 1,500 W	5 / 12 / 24 / 48 VDC, 4:1 wide	1.5 – 8 kVDC options	Instrumentation, distributed rails, medical isolation
Non-Isolated Regulators	0.5 – 50 W	Board-level DC rails	High efficiency point-of-load	Logic rails, sensors, FPGA and MCU supplies
High-Voltage Input DC/DC	5 – 300 W	Up to 310 VDC	Wide-range HV front end	Grid equipment, traction, energy storage
AC/DC Internal (Open / Enclosed)	3 – 3,600 W	85 – 264 VAC	Convection or fan cooled	Machinery, cabinets, test and process systems
AC/DC DIN Rail	10 – 480 W	85 – 264 VAC	35 mm rail, panel-ready	Automation panels, PLC and control systems
External Adapters (Level VI)	2.5 – 250 W	90 – 264 VAC	DoE Level VI / CoC Tier 2	Desktop devices, medical carts, networking

Engineering Experience

Standard, Modified-Standard and Custom Power Supply Design

Wall Industries has designed and manufactured power conversion products in the United States since 1961. Our electrical and mechanical power design engineers apply proven topologies — flyback, forward, LLC resonant, buck and boost — rather than unproven experiments, so that your programme reaches qualification on schedule. Working with long-standing manufacturing partners, we support both prototype volumes and multi-year production releases.

Most enquiries are solved fastest as a modified standard: a qualified catalog platform adjusted for output voltage, connectorisation, cable length, potting, conformal coating, mounting or extended temperature derating. This route preserves existing test data while still delivering a part that fits your product exactly.

For fully custom programmes, engineering begins with your electrical, mechanical, thermal and compliance requirements. If a formal specification does not yet exist, our applications team helps define the input source, worst-case load profile, isolation, cooling strategy and target standards. A preliminary design is submitted for your assessment before manufacturing starts, and designs operating from -55°C to +125°C are available on request.

Our designs are aligned with sector requirements including CISPR/EN emissions limits, UL/IEC 60601-1 for medical equipment and MIL-STD-1275 for military vehicle power. We treat custom programmes as confidential engagements and protect customer intellectual property throughout the project.

Experience You Can Verify

Six decades of shipped power designs across water treatment, grid equipment, industrial lighting, defibrillators, repeaters, microwave links, surveillance and warehouse automation — documented in our published case studies.

Expertise Behind Every Page

Technical articles and application notes are researched with our in-house engineering specialists, fact-checked before publication and reviewed on a regular cycle so specification data stays current.

Accountability & Compliance

Maintained compliance documentation, a published counterfeit-parts policy, environmental sustainability commitments and a code of conduct that governs how we sell, market and support.

Custom Design Programmes

Purpose-Built Power for Regulated Markets

Three dedicated design tracks, each with its own qualification logic, documentation depth and test regime.

Custom Industrial Power Supply Design

Panel, machine and outdoor equipment power with high-temperature derating, sealed or coated builds and long-life capacitor selection for continuous duty.

Industrial design

Custom Medical Power Supply Design

Patient-proximity and body-floating configurations, controlled leakage current, means-of-protection planning and documentation support for device submissions.

Medical design

Custom Military Power Supply Design

Vehicle transient immunity, EMI filtering, conduction cooling, potted assemblies and ruggedised connectors for airborne, ground and shipboard platforms.

Military design

For Global Buyers & Design Teams

How to Specify, Source and Qualify with Wall Industries

1. Define the Requirement

Input source and range, outputs with worst-case and transient current, isolation, ambient temperature, cooling method, envelope, mounting and the safety plus EMC standards your end product must certify to.

Technical library

2. Validate with Real Applications

Review how comparable equipment was powered — commercial water systems, electric power grid hardware, industrial lighting, multiple-output repeaters and surveillance platforms.

Read case studies

3. Buy Through Local Channels

Work with regional sales representatives and authorised distributors for local stock, logistics and after-sales support, or engage our factory team directly for custom programmes.

Authorized distributors

Engineering FAQ

Power Supply Questions Our Engineers Answer Most Often

DC/DC converters are available from 1/2 watt up to 1,500 watts, and AC/DC power supplies from 1 watt up to 3,600 watts. Mechanical formats include encapsulated, PCB through-hole, chassis mount, open frame, enclosed with or without fan, U-frame, DIN rail, wall plug-in and desktop packages.

A modified standard begins with a proven catalog platform and changes only what your application needs — output trim, connectors, harness, potting, coating, labelling or thermal derating. A fully custom design starts from your electrical, mechanical and compliance specification and is engineered from the ground up. Modified standard shortens qualification time and cost; fully custom delivers exact form, fit and function.

Depending on the target market, we design to requirements such as UL/IEC 60601-1 for medical equipment, MIL-STD-1275 for military vehicle power, MIL-STD-461 and CISPR/EN 55032 EMC limits, EN 50155 for rolling stock, and DoE Level VI / EU CoC Tier 2 efficiency rules for external adapters. Compliance documentation is maintained in our resource library.

Yes. On request our engineers design converters and power supplies that operate from -55°C to +125°C using component derating, conformal coating or potting, and conduction-cooled baseplate or chassis construction that removes heat without fans. High-temperature external adapters rated for -40°C to +70°C operation are also available as standard products.

Choose an isolated converter when you must break ground loops, provide safety separation, or create floating rails for measurement and patient-connected circuits. Choose a non-isolated regulator when the source and load already share a reference and your priority is efficiency, density and cost at point of load. If isolation voltage or creepage/clearance requirements are unclear, our engineers can review your architecture.

Yes. Many of our customers build capital equipment with 10 to 20 year service lives. We support form-fit-function replacements for obsolete supplies, second-source designs and long-term production releases, so an end-of-life component in your bill of materials does not force a redesign of the whole product.

Ready to Specify Your Next Power Supply?

Send your requirement to our applications engineering team in Exeter, New Hampshire. We respond with a recommended platform, a modified-standard option, or a custom design path.

Contact Engineering About Wall Industries