Military and Aerospace Battery
A battery system with smarter protection and more stable power delivery.
Engineered for control. Designed for safety.
30% Increase in runtime LiFePO₄ Ruggedized battery system Real-time Control monitoring
Built for extremes
The external connector supports easy field replacement and shields internal wiring from tension and wear during operation.
The board design minimizes electromagnetic interference and supports safe, high-current operation. Onboard firmware enables real-time monitoring and automatic fault handling.
The rigid enclosure blocks dust, debris and impact, helping the unit meet MIL-STD-810 requirements for field durability.
Custom lithium iron phosphate cell pack reduces thermal risk and delivers consistent power without the instability of traditional chemistries.
The design removes heat-trapping plastics and uses internal spacing and materials to support better airflow and cooling during sustained use.
The outer housing was validated through multiple prototype builds and refined to withstand drop, shock and vibration in real-world conditions, including water submersion up to one meter.
Results that make a difference
We increased runtime by 30% with minimal change in size, supporting longer operation in a compact form.
We built diagnostics into the BMS firmware, enabling real-time visibility into battery health, power delivery and fault conditions during use.
We reduced thermal buildup and reinforced the structure to help prevent failure —protecting both the equipment and the people using it.
Project Overview
A battery made for high-discharge operations. Dillon Aero’s high-performance battery system needed updates to its electronics and ruggedness. To help prevent breakage and pass MIL-STD-810, 28 Gorilla redesigned the system’s internal layout, firmware and mechanical housing to improve performance, thermal behavior and system-level protection.
One critical update was the development of a custom battery management system (BMS). A BMS monitors and controls the voltage, current and temperature of lithium-ion cells, protecting the system against overcharging, overheating, short circuits or other failures that can occur during high-discharge operations.
Once engineering was completed, we transferred the updated design to 29Tech, our integrated manufacturing partner, for prototyping and field validation.
The Challenge
Improve safety for unsafe conditions
Dillon Aero needed a more dependable battery for a high-demand application: powering a rotary weapon system.
The system’s internal structure trapped heat, some power connections couldn’t stay secure under vibration, and the electronics offered no safeguards if something went wrong during operation.
Our job was to ensure the battery could regulate power delivery, detect faults and stay operational through real-world strain, all within the same form factor and while maintaining compliance with MIL-STD-810 and 461.
Our Approach
Coordinated mechanical, electrical and firmware engineering
Our electrical engineering team restructured the power delivery system, improving the layout to reduce resistance and heat buildup during high-discharge events. The mechanical team redesigned the enclosure, removing internal plastics that were creating heat traps and strengthening the housing to better withstand vibration and drop impact.
Meanwhile, our firmware developers built a custom BMS to monitor voltage, current and temperature, and to respond automatically to unsafe conditions. This added a critical layer of protection, allowing the battery to shut down safely or regulate output in extreme use cases.
Every decision was aimed at making the battery more stable, predictable and capable of protecting itself during high-demand operation.
Up Close with Military and Aerospace Battery
Skills & Equipment Used
High-discharge layout
EMI mitigation, safe power routing
Compact power systems
Altium, multimeters, thermal tools
Thermal management, impact and vibration resistance
CAD tools, vibration test rigs
Embedded diagnostics, fault-handling logic, LiFePO₄ control
BMS integration
C, bench tools, interface testing