Powering Next Generation Mission-Critical

Defence & Aerospace Platforms

Mission-Critical Power, Engineered Without Compromise

KOLT’s power solutions are engineered from the ground up to meet and exceed stringent MIL standards, ensuring exceptional reliability in extreme environmental and operational conditions. Rather than approaching each program as a one-off custom build with unnecessary risk and variability, we apply a disciplined, repeatable engineering methodology that reduces development time, improves qualification outcomes, and delivers consistent long-term performance.

Operating under an AS9100D certified Quality Management System, we embed rigorous process control, traceability, and continuous improvement into every stage of development and manufacturing. The result is predictable execution, audit-ready compliance, and confidence for prime contractors and defence integrators who demand the highest levels of reliability and accountability.

With over a decade of experience delivering mission-critical power solutions, KOLT provides a trusted European partner capable of supporting complex defence programs with technical excellence, production scalability, and uncompromising quality.

From Bricks to Systems: Vertically Integrated Low Power

What truly sets KOLT apart is the vertical integration we design and manufacture every layer of our power architecture in-house, from the smallest building block to the complete system. This approach ensures strategic independence: our customers are never exposed to third-party supply chain risks or foreign technology dependencies.

At the foundation of our product hierarchy are our proprietary Brick Modules isolated DC/DC converters available in quarter-brick and half-brick form factors, delivering up to 500 W of regulated power. These bricks operate across a wide input voltage range (9–70 V depending on variant) with an extended temperature range down to −55 °C, and feature advanced digital control and communications. They are the core IP that flows upward into every product we build:

From Power Modules to Systems: Vertically Integrated Power for Medium to High Power Applications

For applications demanding kilowatts of continuous power, KOLT’s vertically integrated approach extends to our Power Modules the high-power counterpart to our brick modules. Starting at 2.8 kW per module, these digitally controlled building blocks are the foundation of our rugged AC/DC power supplies and battery chargers. KOLT has three module types designed to build and scale our power in our architecture.

Isolated DC/DC Converter Module

Provides galvanic isolation and precise voltage regulation, stacked with a PFC module to deliver the final isolated output at the required voltage and power level.

Isolated DC/DC Converter Module

Provides galvanic isolation and precise voltage regulation, stacked with a PFC module to deliver the final isolated output at the required voltage and power level.

Combinations of these PFC and DC/DC modules combined together inside a single assembly enable a wide variety of factory-configurable power supplies and battery chargers. This modular approach means your systems can be easily adapted, upgraded, or repaired, minimizing downtime and costs. These power modules flow upward into our complete system-level products:

Just as our bricks power the lower end of the spectrum, KOLT’s power modules sit at the heart of every high-power system we deliver, from multi-channel DC/DC converters for armoured vehicles to three-phase naval battery chargers. Because we design and manufacture these modules ourselves, we control the full value chain from component-level power conversion through final LRU assembly. This deep vertical integration across both design and manufacturing reinforces our strategic independence, ensuring consistent quality, rapid customisation, full traceability, and zero dependence on foreign technology or vulnerable supply chains.

Electrical Design Approach

Reliability is the cornerstone of our electrical design, specifically engineered to prevent the failures you’ve experienced with industrial converters. Our key principles include:

No Moving Parts

Unlike industrial power supplies that rely on mechanical relays to limit inrush current, a common failure point, our designs use MOSFETs. This eliminates relay-related breakdowns, ensuring consistent performance.

Strict Derating Rules

We follow military-grade derating guidelines for transistors and capacitors, reducing component stress and significantly extending product lifespan.

Proven Topologies

Our power converters use widely accepted, thoroughly tested topologies, delivering stability and predictability under all conditions.

These choices directly address the root causes of field failures in industrial converters, such as component fatigue, offering you a dependable solution built for longevity.

Mechanical Design Approach

Harsh environments demand mechanical designs that can withstand extreme conditions that often cause industrial converters to fail. Our approach ensures durability and reliability:

IP68 Fans

For additional cooling, we equip our units with externally mounted IP68-rated fans. These fans are submersible and operate reliably even after water exposure. Multiple fans provide redundancy and enhanced cooling, reducing the risk of heat-related failures.

Machined Aluminum Enclosure

Crafted from a single block of aluminum, our enclosures eliminate the need for screws or sealants around the heatsink. This seamless design enhances ruggedness and prevents ingress.

IP68 Fans

For additional cooling, we equip our units with externally mounted IP68-rated fans. These fans are submersible and operate reliably even after water exposure. Multiple fans provide redundancy and enhanced cooling, reducing the risk of heat-related failures.

Machined Aluminum Enclosure

Crafted from a single block of aluminum, our enclosures eliminate the need for screws or sealants around the heatsink. This seamless design enhances ruggedness and prevents ingress.

Testing Approach

Every KOLT product undergoes a rigorous, multi-stage testing regime before it leaves our facility. Because we design and manufacture in-house, we test at every level of our product hierarchy from individual brick modules and power modules through packaged assemblies and final LRU systems. This layered approach catches defects early and guarantees that each unit performs to specification under real-world conditions.

100% Functional Testing

Every single unit, whether a brick module, a power module, or a complete LRU, is individually tested against its full electrical specification. No sampling, no shortcuts. We verify input voltage range, output regulation, efficiency, protection functions, and digital communications on every device that leaves our production line.

Burn-In

After functional testing, units are subjected to extended burn-in at rated load and elevated temperature. This stress screening eliminates infant mortality failures, ensuring that only units with proven long-term stability are shipped to the field.

Environmental Qualification

Our products are qualified to the full suite of military environmental standards MIL-STD-810 for shock, vibration, humidity, altitude, and temperature extremes; MIL-STD-461 for electromagnetic compatibility; and MIL-STD-704/1275/1399 for electrical power interface compliance. Qualification testing is performed on our own state-of-the-art test equipment, maintaining full control and traceability.

Design Verification and Validation (DV&V)

Beyond production testing, every new design undergoes a comprehensive DV&V campaign that includes thermal characterization, worst-case circuit analysis, HALT (Highly Accelerated Life Testing), and EMI pre-compliance scans. This ensures that our designs carry sufficient margin before they ever enter production.

Quality

KOLT’s quality approach is grounded in the rigorous requirements of the AS9100D aerospace quality management standard, reflecting our commitment to operational excellence, customer satisfaction, and continuous improvement.

We maintain a robust, process-based Quality Management System (QMS) that emphasizes risk management, preventive action, and data-driven decision making across all functions. Through defined procedures, regular internal audits, and clear performance metrics, we ensure consistency, traceability, and compliance with customer and regulatory requirements.

Our teams are empowered with the training, tools, and accountability needed to identify and resolve issues proactively, driving reliability in every product and service we deliver. By embedding quality into our culture and everyday activities, KOLT consistently meets the evolving needs of our aerospace and high-technology customers while sustaining high standards of safety and integrity.