Engineered for control. Designed for safety.
Built for extremes
Results that make a difference
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.
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.
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.
Once validated, we handed the design off to 29Tech for prototype manufacturing and pre-compliance testing aligned with military, environmental and electromagnetic interference (EMI) standards.
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
- MIL-STD-810 and 461 compliance
- UN 38.3 shipping standard
- Field reliability and environmental stress planning
- Prototype test rigs, validation workflows
