One of the largest problems facing designers of powered exoskeletons is the power supply. There are currently few power sources of sufficient energy density to sustain a full-body powered exoskeleton for more than a few hours.Non-rechargeable primary cells tend to have more energy density and store it longer than rechargeable secondary cells, but then replacement cells must be transported into the field for use when the primary cells are depleted, of which may be a special and uncommon type. Rechargeable cells can be reused but may require transporting a charging system into the field, which either must recharge rapidly or the depleted cells need to be able to be swapped out in the field, to be replaced with cells that have been slowly charging.
Internal combustion engine power supplies offer high energy output, but they also typically idle, or continue to operate at a low power level sufficient to keep the engine running, when not actively in use which continuously consumes fuel. Battery based power sources are better at providing instantaneous and modulated power; stored chemical energy is conserved when load requirements cease. Engines which do not idle are possible, but require energy storage for a starting system capable of rapidly accelerating the engine to full operating speed, and the engine must be extremely reliable and never fail to begin running immediately.
Engines which are small and lightweight typically must operate at high speed to extract sufficient energy from a small engine cylinder volume, which both can be difficult to silence and induces vibrations into the overall system. Internal combustion engines can also get extremely hot, which may require additional weight from cooling systems or heat shielding.
Electrochemical fuel cells such as solid oxide fuel cells (SOFC) are also being considered as a power source since they can produce instantaneous energy like batteries and conserve the fuel source when not needed. They can also easily be refueled in the field with liquid fuels such as methanol. However they require high temperatures to function; 600 °C is considered a low operating temperature for SOFCs.
Most research designs are tethered to a much larger separate power source. For a powered exoskeleton that will not need to be used in completely standalone situations such as a battlefield soldier, this limitation may be acceptable, and the suit may be designed to be used with a permanent power umbilical.
