Low-orbit broadband satellite constellations dominate global aerospace competition. Large-scale systems such as China’s StarNet and America’s Starlink deploy thousands to tens of thousands of satellites. Hall thrusters, featuring simple structure, high thrust-to-power ratio, controllable cost and excellent mid-to-low power performance, have become standard for orbit maintenance, deorbiting and attitude control. The high-voltage discharge power supply serves as the core power-processing unit, delivering 200 V–500 V DC for discharge channels and directly determining discharge stability, thrust accuracy and mission lifespan. Large-scale constellation deployment imposes unprecedented requirements: 1.Ultra-high power density and miniaturization: Strict volume and weight limits demand power density ≥300 W/in³ and mass ≤0.8 kg/kW, impossible for conventional discrete aerospace designs. 2.Accurate parallel current sharing and synchronization: Multiple supplies must operate in parallel to avoid current imbalance, overload or thruster shutdown. 3.Balanced low cost and reliability: Mass production requires over 60% cost reduction versus customized aerospace power while maintaining 7–10 year lifespans. 4.High efficiency across wide load ranges: Stable performance from 10% light load for station-keeping to full power for orbit maneuvering is essential to reduce satellite energy consumption. This full-process methodology covers topology design, high-density integration, parallel current sharing, full-range efficiency optimization and mass-production reliability, providing standardized guidelines for domestic constellation Hall thruster power systems. Adopting full-bridge LLC resonant topology with integrated magnetics and modular parallel architecture overcomes traditional conflicts between density, efficiency and reliability. The LLC structure enables full ZVS for primary switches and ZCS for secondary rectifiers with minimal switching loss, high efficiency and compact layout ideal for mass manufacturing. Four core design principles apply: 1.Resonant parameters are optimized for wide Hall thruster load profiles with normalized gain 0.9–1.2 and quality factor Q=0.6–0.8, maintaining soft switching across 80 V–120 V bus and 10%–130% load to eliminate light-load efficiency degradation. 2.Resonant frequency between 150 kHz–300 kHz drastically reduces magnetic component size while controlling core loss with advanced materials. 3.Full-wave synchronous rectification using wide-bandgap devices cuts rectifier loss by over 75%; precise digital timing ensures full ZCS operation. 4.Modular construction supports 100 W–2,000 W per unit with scalable parallel expansion for diverse thruster thrust levels and streamlined mass assembly. Ultra-high power density integration is achieved through three key strategies: Integrated magnetics merge resonant inductance, magnetizing inductance and transformer within a single core, reducing size by ≥45% and mass by ≥40%. Nanocrystalline cores deliver low high-frequency loss (≤200 mW/cm³ at 200 kHz); flexible multilayer PCB windings achieve leakage inductance ≤2 μH and coupling ≥0.998. High-thermal-conductivity epoxy potting dissipates heat efficiently within compact assemblies. Three-dimensional stacking adopts power layer + control layer + filter layer vertical architecture, improving space utilization by ≥60%, shortening power loops and minimizing parasitic inductance. High-density surface-mount layout uses multi-layer heavy-copper PCBs with bare-die power devices directly bonded for ultra-compact thermal conduction to the integrated aluminum housing, achieving final power density ≥320 W/in³ and mass ≤0.75 kg/kW. Precise multi-module parallel current sharing employs hybrid digital master-slave + droop compensation, ensuring ≤±2% current accuracy across all loads: CAN bus coordinated master-slave control distributes current references dynamically with automatic master redundancy switching. Adaptive voltage droop compensates line impedance to maintain ≤±0.3% output precision and balances thermal distribution with ≤5 ℃ temperature deviation among parallel units. Nanosecond synchronization (≤100 ns) eliminates circulating current and EMI; fast interlocking protection shuts down parallel units within 1 μs during faults to safeguard thrusters and satellites. Full-range efficiency optimization and mass-production reliability enhance practical deployment: Full SiC wide-bandgap semiconductors reduce primary switching loss by ≥65%; optimized stacked busbars limit parasitic inductance ≤5 nH; intelligent digital tuning maintains peak efficiency ≥96.5% at full load and ≥95% from 10%–100% load. Cost-effective reliability adopts Level-I component derating, redundant filtering/drive circuits and radiation-hardened industrial components (≥50 krad(Si)), cutting cost by over 65% while meeting 10-year radiation endurance. Fully standardized surface-mount automated assembly accelerates production by ≥80%, supporting tens-of-thousands satellite manufacturing. Comprehensive in-orbit monitoring and protection ensure long-term constellation stability: Full telemetry captures voltage, current, temperature and operational status via CAN bus with fault logging for traceability. Multi-level hardware/software protection covers overvoltage, overcurrent, short-circuit, overtemperature, arcing and thruster flameout interlock with sub-1 μs response; faulty modules automatically isolate without disrupting parallel operation. In summary, this framework resolves traditional weaknesses of low density, high cost and poor scalability. Integrated magnetics and 3D packaging deliver extreme compactness; intelligent parallel control guarantees stable multi-thruster operation; standardized low-cost design enables massive constellation rollout. It provides core domestic technical support for large-scale low-orbit broadband satellite networks.