By Robert Pecaric Jr., President & CEO, Aerospace Devices Inc. | 2024 Aerospace & Defense Reviews USB Charging Company of the Year
Last month, I walked our factory floor in Wichita and watched our team test a waterproof marine-grade USB charging port that had just survived environmental testing. The housing was scuffed, the labels worn, but it was still charging at full output after surviving temperature swings that would shut down most consumer electronics. That’s when it hit me: what we build isn’t just hardware. It’s infrastructure that keeps critical systems running when everything else is fighting to survive.
I’ve spent fifteen years in aerospace equipment manufacturing, and the shift I’ve witnessed is remarkable. Power systems used to be tucked into panels and forgotten. Today, aerospace charging solutions are engineered with the same rigor as avionics because a failed EFB mid-approach is as serious as any instrument malfunction.
The Reality of Modern Aircraft Power Demands
When my father founded this company, pilots carried paper charts. Today, a single cockpit might power three EFBs, two tablets, passenger devices, and backup communication gear—all drawing from the same electrical bus. The math gets tight fast.
The problem isn’t just total power draw. It’s voltage stability, heat management, and electromagnetic compatibility. A charger that works beautifully in a hangar can become a liability at 35,000 feet when cabin pressure drops, and temperatures swing wildly.
Our answer was to stop thinking like consumer electronics manufacturers and start thinking like the aerospace equipment manufacturing partners we are. That meant re-engineering from the ground up.
What “Marine-Grade” Actually Means for Aviation
We get questions about our waterproof marine-grade USB charging port designs. Some assume it’s overkill for aircraft until they see the condensation forming in unpressurized compartments or the fluid exposure during maintenance.
Marine-grade sealing isn’t about submersion. It’s about environmental resilience. Our IP67-rated housings use CNC-machined 6061-T6 aluminum with dual O-ring seals and potted internal electronics. We’ve watched these units shrug off pressure washing during heavy maintenance checks and keep delivering clean 5V output.
The specification matters because failure modes in aviation cascade. A shorted charging port doesn’t just inconvenience a passenger; it can trip breakers, affect bus loading, and create distractions when focus matters most.
Voltage Flexibility: The 12VDC to 32VDC Challenge
One of our most requested configurations is the 12VDC-to-32VDC input USB-C charger. The range seems wide until you understand aircraft electrical systems.
General aviation aircraft typically run 14V or 28V nominal systems. Military platforms might see 24V. Add in engine starting loads, alternator fluctuations, and ground power variations, and that “12V” port might see anything from 10V spikes to 32V transients.
Our SkyDock Pro line uses wide-input DC-DC converters with active power factor correction. Translation: stable USB Power Delivery output, whether you’re starting a cold engine in Minnesota or running ground ops in Dubai. The circuitry compensates automatically— no manual switching, no user intervention required.
We’ve tested these units against DO-160G Section 16 power input variations. They hold specification when voltage sags to 8V or spikes to 36V. That’s not theoretical; it’s what we verify in our Wichita test lab before any design sees production.
Heat: The Silent Performance Killer
Here’s something consumer charger manufacturers don’t talk about: efficiency losses become heat, and heat becomes failure.
A typical consumer USB-C charger runs 65-70% efficient. The other 30-35% becomes waste heat— fine in air-conditioned homes, problematic in confined avionics bays. Our aerospace designs achieve 90-93% efficiency at 20V/5A output. That 25-point improvement means less thermal load, smaller cooling requirements, and longer component life.
We achieve this through synchronous rectification, forced-PWM mode switching, and thermal management built into the housing design itself. The aluminum enclosure isn’t just rugged; it’s a heat sink that keeps internal components within specification.
Certification as Foundation, Not Afterthought
I mentioned DO-160G testing earlier. For those unfamiliar, it’s the RTCA standard that defines environmental conditions for airborne equipment. Twenty-six test categories covering temperature, altitude, vibration, humidity, salt spray, EMI, and more.
We don’t certify “after” design. We design for certification from the first schematic. Every component selection, every trace width, and every mounting hole location considers the test requirements it must survive. Our current SkyDock Pro series carries DO-160G qualification, and we’re actively pursuing FAA TSO C71 approval, an additional layer of scrutiny that matters for permanent aircraft installation.
This certification-obsessed approach isn’t bureaucratic box-checking. It’s how we ensure that when a pilot plugs in an EFB before an instrument approach, that device stays powered through the entire procedure.
Where Aerospace Charging Solutions Are Heading
Looking ahead, aerospace charging solutions are evolving in three directions we’re actively developing:
- Higher power density: USB Power Delivery 3.1 now supports 240W, enough for laptops and larger displays. We’re prototyping compact 100W+ modules that fit standard panel cutouts without requiring larger installation footprints.
- Intelligent power management: Chargers that communicate with aircraft systems, reporting load status and enabling remote monitoring. This matters for electric aircraft and platforms with tight power budgets.
- Sustainability integration: EU PED compliance requirements are expanding. Our designs now emphasize efficiency metrics and e-waste reduction through modular construction— replaceable ports instead of disposable units.
Built in Wichita, Tested Everywhere
I started this piece on our factory floor, so I’ll end there too. When you buy from Aerospace Devices, you’re not getting a rebranded consumer product with an aviation markup. You’re getting hardware designed, machined, assembled, and tested in Wichita, Kansas—the Air Capital of the World—by people who understand that “flight-critical” isn’t marketing language. It’s a commitment.
Our 2024 recognition from Aerospace & Defense Reviews validated what our customers already knew: American aerospace equipment manufacturing, done right, still leads this industry.
Ready to specify aerospace-grade charging for your platform? Contact our engineering team for technical documentation and integration support.
FAQs
Q: What’s the difference between a marine-grade and standard aviation USB charger?
→ Marine-grade specifications emphasize environmental sealing against moisture, salt, and pressure washing— challenges also present in aircraft during maintenance and in unpressurized compartments. Our IP67-rated designs use the same sealing technology for both applications, ensuring reliability across conditions.
Q: Why does the input voltage range matter for aircraft USB chargers?
→ Aircraft electrical systems experience significant voltage variation during engine starting, alternator loading, and ground power transitions. A charger rated only for “12V” or “24V” nominal may fail or produce unstable output during these transients. Wide-range 12VDC to 32VDC input designs maintain consistent performance across all operating conditions.
Q: How does DO-160G certification affect charger selection?
→ DO-160G certification verifies that equipment can survive the environmental stresses of flight—temperature extremes, vibration, altitude, humidity, and electromagnetic interference. For charging systems powering EFBs or other flight-critical devices, this certification provides assurance that power will remain available when needed.
Q: Can I install these chargers in certified aircraft?
→ Installation requirements vary by aircraft type and regulatory jurisdiction. Our DO-160 G-qualified units are suitable for many installations, and we’re pursuing FAA TSO C71 certification for broader approval. We recommend consulting your A&P mechanic or completion center for specific aircraft applications, and our Wichita team provides technical support for installation planning.
