ELECTRICAL SYSTEM DESIGN
Expert electrical design services for automotive and off-grid applications, covering everything from system architecture to high-voltage DC and 230V AC systems.
We specialise in comprehensive electrical design solutions tailored for both automotive and off-grid applications. Our capabilities include complete component and system-level design, architecture and schematic development, cable and harness design, and control systems engineering. We seamlessly integrate third-party products and specialise in complex power systems. Whether it's a new build or integration into an existing platform, we deliver reliable, scalable, and standards-compliant designs.
Frequently Asked Questions
A power distribution system manages the routing of DC and AC electrical power from sources such as batteries, and shore power to circuits and loads within your vehicle, vessels, or off-grid application. Merlin Power specialises in the design and supply of power distribution systems that integrate switches, fuse blocks, circuit breakers, busbars, connectors, and power posts, all engineered for safety, reliability, and ease of install and maintenance.
Costs vary depending on the complexity of the system, the number of circuits, the components specified, and whether design and installation services are required. Merlin Power can supply everything from individual fuse blocks and distribution components to fully engineered and integrated systems. A well designed system eliminates unnecessary future repair costs, meaning an initial investment will save you money later down the line. Contact the team to discuss your project and receive a tailored solution and quotation, or explore their electrical system design service for a complete turnkey approach.
A properly designed distribution system primarily ensures safety of your electrical system, both protecting the user and the equipment itself. This inherently means that every load receives the right voltage and current, that any potential faults are contained, and that the system can be safely operated, maintained and modified. Merlin Power's ISO 9001-accredited design process delivers standards-compliant, scalable distribution solutions trusted by military, emergency service, and commercial fleet operators.
Power flows from the source through a distribution board or busbar, protected by correctly rated fuses or circuit breakers, and then on to individual circuits and loads. Merlin Power's electrical system design team develops bespoke distribution architectures for automotive and off-grid applications, covering DC and 230V AC systems, with full schematic documentation and compliance validation.
Electrical manufacturing at Merlin Power involves the design, production, and assembly of electrical systems, wiring harnesses, control panels, and power management units. Based in Exeter with over 35 years of experience, Merlin Power manufactures products and systems for some of the world's most demanding applications, including military land platforms, emergency service vehicles, and luxury yachts. See their full electrical system design capability for details
Merlin Power's electrical manufacturing process encompasses system architecture, schematic development, component sourcing, cable and harness design, and final assembly. The team holds ISO 9001 and ISO 14001 certifications, ensuring consistent quality and environmental responsibility throughout. Every manufactured system is functionally tested and validated before delivery. For mechanical enclosure work alongside electrical assembly, explore their rapid prototyping service, a process designed to support urgent operational requirements.
Costs depend on the complexity, volume, and specifications of the required system or assembly. Merlin Power works with clients at all scales, from single bespoke units to fleets of 500+ vehicles. Related services such as system integration and bespoke installation are also available. Contact the team to discuss your project scope and receive a tailored quotation.