When industrial electronic equipment operates under severe environmental stress, standard commercial power supplies quickly experience catastrophic failure. Factors such as conductive metallic dust in underground mining, continuous high-amplitude mechanical vibration in rolling stock, high humidity in subsea ROVs, and corrosive airborne chemicals rapidly degrade unsealed circuit boards. ABSOPULSE Electronics addresses these critical survival challenges through our custom and standard lines of Fully Encapsulated Heavy-Duty DC-DC Converters.
For over four decades, our Ottawa engineering team has perfected the design, thermal management, and manufacture of completely potted power converters. By encapsulating high-frequency switch-mode power topologies inside specialized thermally conductive silicone, epoxy, or polyurethane compounds, our converters achieve total immunity against moisture, oil, salt fog, airborne dust, and insects. In addition, the solid potting mass provides structural support for internal magnetics and surface-mount components, allowing them to resist mechanical shock loads exceeding MIL-STD-810G requirements.
A technical evaluation of thermal conductivity, mechanical dampening, coefficient of thermal expansion (CTE) matching, and electrical breakdown isolation.
Conformal coating leaves microscopic voids around component leads and high-profile magnetics where corrosive agents collect. Full potting fills every air cavity, eliminating moisture condensation, dendritic growth, and arc-over caused by conductive dust or sulfur-bearing industrial fumes.
Air is a thermal insulator (λ ≈ 0.026 W/m·K). By displacing trapped air with high-grade thermally conductive potting compounds (up to 1.2 to 2.5 W/m·K), heat generated by power MOSFETs, magnetic cores, and rectifiers transfers directly to the aluminum chassis baseplate for fanless conduction cooling.
In mobile applications, continuous vibration causes solder fatigue and physical detachment of heavy inductors or capacitors. Encapsulation locks every component in a rubberized, energy-absorbing matrix, dampening acoustic noise and preventing mechanical fatigue under extreme G-force events.
Engineered platforms customizable for output voltage regulation, input wide-range ratios, mechanical footprints, and specialized connector interfaces.
400W Fully Encapsulated Module
Features wide DC input ranges (24V, 48V, 72V, 125Vdc), IP66 die-cast aluminum housing, conduction/convection cooling, and complete isolation for heavy mining and utility equipment.
EN50155 Railway Compliant
Fully potted railway DC-DC converters rated from 50W to 1000W. Operates continuously under severe shock and vibration on rolling stock, trackside signals, and electric buses.
250W Step-Up / Boost Encapsulated
Equipped with heavy-duty heat-sink assembly fins. Designed to step up low battery voltages while sealed against environmental exposure in outdoor substations.
1500W High-Output DC-DC Platform
High-density, ruggedized chassis with potted magnetic assemblies, wide-range inputs, and parallel operation capability for high-current industrial payloads.
Review standard engineering specifications across core ABSOPULSE encapsulated converter product lines.
| Series Platform | Power Output | Input Voltage Ranges (Vdc) | Output Voltage Options | Environmental Sealing & Cooling | Target Certifications |
|---|---|---|---|---|---|
| PDC 250-P300 | 250W | 14–30V, 20–60V, 43–105V, 90–140V | 12V, 24V, 48V, 125Vdc | IP66 Encapsulated, Die-cast Aluminium, Conduction/Convection | EN62368-1, CE, IEC60529 IP66 |
| PDC 400-P400 | 400W | 24V, 48V, 72V, 110V, 250V (Custom wide-range) | 12V, 24V, 48V, 125Vdc | Fully Potted, Heavy-duty Chassis, Baseplate Conduction | MIL-STD-810G vibration, EN62368-1 |
| RWY 100-P500 | 100W | 14–30V, 36–72V, 66–154V rail inputs | 5V, 12V, 15V, 24V, 48Vdc | Fully Potted IP66 Enclosure, Conduction cooled baseplate | EN50155, RIA12, EN45545-2 |
| HWR 300 Series | 300W | 24V, 36V, 48V, 72V, 96V, 110Vdc | 12V, 24V, 48Vdc | Full Potting Resin, IP67 Connectors optional | EN50155, IEC61373 Shock/Vib |
| CSI 200-P500 (DC-DC/DC-AC) | 200VA / W | 24V, 48V, 110V, 250Vdc | 12V, 24Vdc or 115V/230Vac pure sine | Fully Encapsulated Enclosure, Baseplate Cooling | IEEE 1547, EN60950-1, IP66 |
As industrial electrification accelerates across autonomous heavy equipment, zero-emission marine vessels, smart traction networks, and high-voltage energy storage systems (BESS), procurement managers and system integrators face evolving technical demands for auxiliary DC-DC power conversion.
Next-generation fully encapsulated converters utilize Silicon Carbide (SiC) and Gallium Nitride (GaN) switching transistors. Higher switching frequencies reduce the physical volume of magnetic cores and capacitors, yielding higher power densities. When combined with thermally conductive potting, SiC/GaN devices dissipate minimal energy while maintaining elevated temperature tolerance.
Global equipment platforms require standardized DC-DC converters capable of operating across diverse DC bus voltages (e.g., spanning 14Vdc to 160Vdc continuously). Wide input capability minimizes SKU proliferation for global OEMs while accommodating extreme voltage sags and surge transients during heavy motor starting.
Modern B2B procurement demands remote diagnostic visibility. Future encapsulated converters integrate isolated CANbus, PMBus, or Modbus digital interfaces directly within the potting compound, enabling predictive maintenance, thermal logging, and dynamic output adjustments without compromising electrical isolation.
Environmental directives are driving transition toward non-toxic, flame-retardant (UL94-V0 rated) encapsulating polymers that emit zero halogen fumes under extreme fire conditions (EN45545-2 compliant for passenger rail safety).
Over 40 years of dedicated power electronics design, in-house Canadian manufacturing, zero optocoupler topology designs, and total quality control.
Unlike distributors who source off-the-shelf modules, ABSOPULSE winds custom transformers and executes precise multi-stage vacuum encapsulation in our 80,000 sq ft Ottawa facility.
We purposefully eliminate short-lived optocouplers from feedback loops and conservatively derate power semiconductors to deliver up to 30 years of continuous service life in harsh environments.
From custom input/output connector pinouts to wide-range DC inputs, custom chassis mounting dimensions, and specialized thermal heatsinks, our engineering team tailors platforms to your system envelope.
In-depth engineering answers to high-intent technical questions asked by systems architects and global procurement managers.
Open-frame power supplies rely on air circulation, making them vulnerable to ambient humidity, conductive metallic dust, aggressive airborne chemicals, and insects. Conformal coating provides thin-film surface protection against moisture, but it leaves tiny air voids around large magnetic components, leads, and heatsinks. In contrast, a fully encapsulated (potted) DC-DC converter completely submerges internal circuit boards and components in a solid compound. This eliminates all internal air pockets, provides high dielectric breakdown isolation, protects against chemical atmospheric corrosion, transfers heat effectively to the outer chassis without internal fans, and locks heavy components in place to endure intense vibration and impact shock loads.
Encapsulated converters utilize specialized thermally conductive potting resins (polyurethane, silicone, or epoxy matrices filled with metallic oxide powders). Heat generated by power semiconductors, magnetic cores, and power resistors is rapidly conducted away from hot spots, spreading evenly throughout the entire solid encapsulation mass toward the outer aluminum baseplate or extruded heatsink fins. The heat is then dissipated into the host equipment chassis via conduction or into the ambient air via natural convection. This fanless thermal architecture removes the single primary point of failure in power supplies (the cooling fan), enabling reliable continuous operation across extended temperature ranges from -40°C to +85°C.
When electronic assemblies undergo rapid thermal cycling (e.g., from -40°C start-up to +85°C full-load operation), materials expand and contract at different rates. Rigid potting materials can exert high mechanical stresses on SMD components, ceramic capacitors, and fine transformer wire leads, causing micro-cracking or solder fatigue over time. ABSOPULSE prevents CTE stress failure by specifying elastomeric silicone and flexible polyurethane potting compounds engineered with high elasticity and low glass transition temperatures (Tg). These rubberized compounds cushion internal components, absorbing differential expansion forces without cracking delicate surface-mount devices or solder joints.
Depending on target system requirements, our heavy-duty potted platforms can be designed and tested to meet international industry standards: Railway Rolling Stock (EN50155, EN50121-3-2 EMC, IEC61373 Shock/Vibration, RIA12 surge protection), Military/Defence (MIL-STD-810G vibration/shock, MIL-STD-461 EMC), Environmental Protection (IEC60529 IP66/IP67 ingress ratings), Electrical Safety (EN62368-1 / IEC60950-1), and Passenger Rail Fire Safety (EN45545-2 R22/HL3 toxicity and flame propagation resistance).
Yes. ABSOPULSE is primarily a custom power supply design house. Over 80% of our production volume consists of custom or semi-custom power conversion designs. Our Ottawa-based engineering team can adapt standard encapsulated topologies to accommodate non-standard DC input voltages (ranging from low 12Vdc batteries up to 1000Vdc solar or traction lines), multiple isolated DC outputs, custom voltage trimming, specialized IP-rated circular connectors, or unique mounting mounting dimensions for existing mechanical cutouts.
To initiate a technical consultation or request a formal technical proposal, simply click the Get Catalog button on this page to open our interactive engineering support window. Alternatively, submit your project input voltage range, required output voltage/current, target operating temperature, mounting envelope constraints, and estimated annual volume directly to our engineering sales group at [email protected].
Connect with our technical design team in Ottawa, Canada to review your environmental, electrical, and thermal requirements.