Global demand for electricity is rising fast. Energy-hungry data centres 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 1,200V, 400A module is well suited for data centres, 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 30,000ft 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."
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.
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 a broad impact across multiple sectors.
In the US 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's 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 take-off 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's ultralow inductance and durable design make it well suited for that challenge.