Global demand for electricity is rising fast. Energy-hungry data centers that support artificial intelligence, along with expanding manufacturing, are putting unprecedented pressure on power systems worldwide. Meeting that demand will require more than simply generating additional electricity.
One promising solution is to use existing energy supplies far more efficiently and at lower cost.
A New Approach to Power Efficiency
Researchers at the National Renewable Energy Laboratory (NREL) have developed a new silicon carbide based power module designed to dramatically improve how electricity is converted and delivered. A power module is the housing that contains power electronics, which regulate the flow of electricity between systems. This new design delivers record-breaking efficiency, higher power density, and a manufacturing process that keeps costs low.
The technology is known as NREL’s Ultra-Low Inductance Smart power module, or ULIS. By using silicon carbide semiconductors, ULIS can achieve five times the energy density of earlier designs while taking up less space. That combination allows manufacturers to build equipment that is smaller, lighter, and more energy efficient. The 1200-volt, 400-amp module is well suited for data centers, electrical grids, microreactors, and heavy-duty platforms such as next-generation aircraft and military vehicles.
Why Ultra-Low Inductance Matters
A key advantage of ULIS is its exceptionally low parasitic inductance, which refers to resistance that slows changes in electrical current and limits efficient power conversion. ULIS reduces this resistance by seven to nine times compared with today’s most advanced silicon carbide power modules.
Because the system can switch electrical current extremely quickly and efficiently, it converts more of the available electricity into usable power. That capability allows ULIS to extract significantly more value from the same energy supply, making it a strong candidate for addressing growing global energy needs.
“We consider ULIS to be a true breakthrough,” said Faisal Khan, NREL’s chief power electronics researcher and the principal investigator for the project. “It’s a future-proofed, ultrafast power module that will make the next generation of power converters more affordable, efficient, and compact.”
Built for Reliability in Extreme Conditions
ULIS is designed not only for efficiency, but also for reliability in demanding environments. According to Khan, the lightweight yet powerful module can monitor its own condition and anticipate component failures before they happen.
This feature is especially critical for high-risk applications such as aviation and military operations. For aircraft operating at 30,000 feet or vehicles navigating combat zones, early failure detection can be the difference between mission success and catastrophic loss.
“ULIS was a truly organic effort, built entirely in-house here at NREL,” Khan said. “We are very excited to demonstrate its strengths in real-world settings.”
A Radical Redesign for Lower Cost Manufacturing
Many of ULIS’ performance gains come from a completely new physical design.
Traditional power modules stack semiconductor devices inside box-like packages. ULIS instead arranges its circuitry in a flat, octagonal layout. This disk-shaped structure fits more components into a smaller footprint, reducing both size and weight. At the same time, its innovative current routing minimizes magnetic interference, which helps deliver cleaner electrical output and higher overall efficiency.
“Our biggest concern was that the device switches off and on very quickly, and we needed a layout that wouldn’t create a chokepoint within the design,” said Shuofeng Zhao, an NREL power electronics researcher who designed ULIS’ flux cancellation architecture.
Early concepts explored complex three-dimensional shapes, including designs resembling flowers or hollow cylinders. However, these ideas proved too expensive or difficult to manufacture. The breakthrough came when the team simplified the concept into a nearly two-dimensional structure. Sarwar Islam, another NREL power electronics researcher, proposed the flattened design that balanced performance, cost, and manufacturability.
“We squished it flat, like a pancake,” Zhao said, “and suddenly we had a low-cost, high-performing design that was much easier to fabricate.”
Joshua Major, also part of the NREL power electronics team, developed new fabrication methods that allowed the intricate structure to be produced using only in-house tools and facilities. The result was a design that combined the electrical advantages of three-dimensional systems with the practicality of flat manufacturing.
Flexible Materials and Wireless Control
ULIS also departs from conventional materials. Traditional power modules bond copper directly to rigid ceramic bases to conduct electricity and manage heat. While effective, this approach limits flexibility.
Instead, ULIS bonds copper to a flexible polymer called Temprion. This change produces a thinner, lighter, and more adaptable structure. The material bonds to copper using only heat and pressure, and its components can be machined with widely available equipment. As a result, manufacturing costs fall into the hundreds of dollars rather than the thousands.
Another major advance allows ULIS to operate wirelessly. The module can be controlled and monitored without physical cables, functioning as a self-contained unit. This modular, Lego-like design allows it to be integrated into a wide range of systems, from data center servers to advanced aircraft and military vehicles. A patent for the low-latency wireless communication protocol, led by Sarwar Islam, is currently pending.
Designed for Future Technologies
While ULIS currently relies on advanced silicon carbide semiconductors, the design was intentionally built to evolve. The module can be adapted for future semiconductor materials, including gallium nitride and gallium oxide, which has not yet reached commercial use.
Together, these innovations support a central goal. As societies become increasingly dependent on reliable electricity, ULIS is designed to deliver efficiency without sacrificing dependability.
Where ULIS Could Make the Biggest Difference
ULIS is expected to have broad impact across multiple sectors.
In the U.S. power grid, electricity must be converted into usable forms before it reaches consumers. This process often depends on large, low-frequency equipment that wastes energy. ULIS’ fast switching improves efficiency while its ability to tolerate high temperatures may reduce long-term maintenance costs.
In aviation, the module’s ability to move electricity quickly and conserve energy enables lighter and more powerful converters. This could help make electric vertical takeoff and landing (eVTOL) aircraft more practical and commercially viable.
ULIS could also play a role in future fusion energy systems. Although commercial fusion remains under development, these systems will require compact and reliable pulsed power components. ULIS’ ultralow inductance and durable design make it well suited for that challenge.
As industries pursue more reliable electricity, advanced artificial intelligence, and next-generation vehicles, ULIS is now available for licensing.
