USB-C power delivery for military portable systems

This study evaluates the potential of USB Type-C Power Delivery (USB PD) as a standardized charging solution for military portable power systems. Two lithium-ion battery configurations (4S1P and 4S3P) were designed, constructed, and tested under light, medium, and heavy load profiles. The 4S3P configuration delivered up to 9.24 Ah capacity and 252 min discharge duration, outperforming the 4S1P design while maintaining safe thermal limits (58 ° C ). Comparative analysis against legacy nickel–cadmium packs demonstrated substantial improvements in energy density, charging flexibility, and interoperability. A dataset of 73 military-representative devices was analyzed using multivariable regression ( R 2 = 0.8604), identifying legacy charge time as the strongest predictor of efficiency gains. Median charging time reduction was 73.3%, with most devices achieving 50%–90% faster charging under USB PD. Squad-level simulations translated these device-level improvements into an aggregate 78.8 h reduction in total charging time per nine-person squad during a 72 h mission, reducing logistical burden and improving equipment availability. The findings confirm that USB PD adoption can enhance operational readiness by streamlining charging infrastructure, reducing downtime, and minimizing the weight and complexity of battery logistics. Future research should assess long-term reliability under extreme environmental conditions and examine integration with emerging military energy systems. • USB Type-C Power Delivery integrated into soldier-portable Li-ion packs (4S1P, 4S3P). • 4S3P delivers up to 9.24 Ah and 252 min; 4S1P recharges faster with lower mass. • Across 73 devices, USB PD cuts median charge time by 73.3% versus legacy. • Regression (R 2 =0.8604) finds legacy charge time the dominant predictor of gains. • Squad-level model shows 78.8 h less total charging during a 72 h mission.