Boeing and Avilution unveil Battery Mesh System prototype for future military power networks

Boeing and Avilution will demonstrate a working prototype of a Battery Mesh System (BMS) at SOF Week that consolidates generators and mixed battery types into a single, mobile electrical distribution system to improve mission endurance and simplify sustainment for U.S. Army ground units.

On display at SOF Week

• Interconnected generators and energy-storage units of varied chemistries and form factors into a unified, transportable power network.
• Support for AC and DC power and a range of voltages and currents used by U.S. Army equipment.
• Modular, upgradable hardware along with system architecture and control concepts.

Software supremacy

Boeing is partnering with Avilution to integrate BMS using Avilution’s eXtensible Flight System (XFS). XFS is a modular, interoperable, and reconfigurable architecture proven in safety-critical flight systems. Its maturity and reliability reduce technical risk for BMS integration while delivering control and monitoring capabilities for operational use.

“This effort with Boeing demonstrates an expansion of Avilution's eXtensible Flight System from crewed flight into battery management systems. It shows how XFS technology can economically bring the safety and reliability of flight qualified systems to other industries, opening new opportunities for scalable, configurable control architectures,” said Mark Spencer, Avilution founder and XFS architect.

The prototype demonstrates a near-term path to lower generator fuel use and simplify logistics by consolidating incompatible batteries and chargers into a single, manageable system, while redundant distribution paths and flexible routing improve power resilience and mission endurance.

How it works

• Mesh design creates redundant distribution paths and enables real-time load balancing.
• Dynamic reconfiguration routes energy to match demand and battery state of charge.
• Supports mixed battery chemistries and a range of voltages and currents required by U.S. Army equipment and vehicles.
• Transportable hardware and scalable software allow the system to move with mobile ground units.

Operational benefits

The Battery Mesh System provides a practical alternative to the current fragmented mix of generators, batteries, and chargers — offering an affordable, upgradable, and resilient architecture that can evolve with changing threats and operational needs. The SOF Week prototype moves the concept into tangible hardware and helps pave a path for further testing and potential fielding.

“The system complements Boeing Global Services’ Agile Sustainment initiatives,” said John Chicoli, senior director, U.S. Army/Marine Corps & Special Ops/Missions & DLA Support Services, Boeing Global Services. “Modular hardware and software-enabled systems can transform sustainment and operational readiness — delivering faster turnarounds, fewer on-hand spares, and more time on station for warfighters.”