A new wave of satellite constellations circling Earth’s low orbit is quietly reshaping the requirements for electronic components in space. Instead of a handful of large, ultra-expensive spacecraft, the modern “new space” ecosystem relies on fleets of smaller satellites that must still endure radiation, extreme temperatures, and long operational cycles. In response to this shift, Micross Components has expanded its Hi-Rel power solutions portfolio with the new AFLS28XX Series — a Class H+ screened DC-DC converter family designed specifically for the evolving needs of LEO missions.
At its core, the AFLS series is a 28-volt, 120-watt radiation-tolerant converter platform intended for satellite constellations, launch vehicles, and other space-based systems where reliability remains critical but budgets and scale increasingly matter. The design builds upon the company’s earlier AFL converter architecture, a platform with extensive flight heritage in demanding defense systems including Patriot Missile System and PAC‑3 Missile System. That legacy gave engineers a starting point already proven in high-reliability environments, which they then modernized with updated components and refined design approaches suited for the new space market.
One of the central engineering challenges in orbit is radiation exposure. Electronic systems in LEO constantly face ionizing radiation and high-energy particle events that can degrade or disrupt circuits over time. The AFLS converters address this by offering radiation tolerance specifications of 50kRad (Si) total ionizing dose and single-event effect resilience up to 60 MeV·cm²/mg. This level of protection places them squarely in the category of radiation-tolerant hardware suitable for long-duration LEO missions without the full cost structure associated with the most stringent deep-space qualification standards.
Reliability screening follows the rigorous MIL-PRF-38534 Class H process, which includes testing steps such as particle impact noise detection and radiographic inspection to ensure structural and manufacturing integrity. Those procedures matter because once hardware leaves Earth, repair is not an option; every component must survive the entire mission lifecycle without intervention.
Physically, the converters are hermetically sealed to protect internal electronics from environmental stress and contamination. They are available in both single-output and dual-output configurations with voltages ranging from 5V to 28V, offering flexibility for satellite subsystems such as communication payloads, onboard processing, and sensor arrays.
From a systems-engineering perspective, the AFLS design emphasizes improvements in SWaP — size, weight, and power — a metric that aerospace engineers obsess over for good reason. By reducing power consumption and eliminating the need for additional radiation shielding, the converters help spacecraft designers shrink overall system mass while maintaining performance. High power density and the ability to operate without derating across the full temperature range further simplify integration into compact satellite platforms.
The converters also support parallel operation for power outputs above 120 watts. Built-in current sharing ensures balanced load distribution between modules, while synchronization capability with system clocks in the roughly 525 kHz range allows stable operation within complex spacecraft power architectures.
According to Micross CTO Richard Locarni, the AFLS series was developed to address the growing tension between reliability and cost in modern space programs. Traditional fully space-qualified power supplies remain extremely expensive and time-consuming to produce, while commercial-grade electronics often introduce unacceptable mission risk. Radiation-tolerant solutions like AFLS aim to bridge that gap by providing high reliability without the full burden of legacy qualification processes.
Engineering samples of the new converters are currently in testing, with availability expected within four to six weeks after receipt of order. For satellite developers building next-generation constellations, components like these represent a small but essential piece of the infrastructure enabling the expanding orbital economy.