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Global energy demand is rising rapidly, fueled by power-hungry data centers supporting artificial intelligence (AI) and expanding industrial manufacturing. Meeting this growing need has become a pressing challenge, prompting engineers to explore ways to use electricity more efficiently and cost-effectively.

In response, researchers at the National Laboratory of the Rockies (NREL) have developed the Ultra-Low Inductance Smart power module, or ULIS. Built with silicon carbide semiconductors, ULIS houses the electronics that regulate electricity between systems, achieving unprecedented efficiency, power density, and manufacturability.

The module delivers five times the energy density of previous designs while taking up less space, enabling manufacturing solutions that produce lighter, more compact, and energy-efficient equipment. Rated at 1200 volts and 400 amperes, ULIS is designed for demanding applications, from electric grids to microreactors and heavy-duty platforms, highlighting advanced engineering capabilities.

(Also read: Top Semiconductor Breakthroughs of 2025)

 Top 7 Advantages of the ULIS Module

ULIS offers several advantages that can transform efficiency and performance across manufacturing industries.

• Minimal unwanted inductance

ULIS has an extremely low parasitic inductance, which normally slows how quickly electrical current can change and limits power conversion. Compared with leading silicon carbide modules, ULIS reduces this resistance by seven to nine times. Its ability to switch current rapidly and efficiently allows it to deliver more usable power from the same electricity supply. Its design also supports rigorous reliability testing, making ULIS a strong energy solution.

• Built for tough conditions

Rising above 30,000 feet or navigating rugged combat zones, ULIS keeps power flowing where it matters most. Lightweight yet powerful, the module monitors its own performance and predicts potential failures. Its design makes it exceptionally reliable for aviation and aerospace, military systems, and other high-stress environments where consistent operation is critical.

• Unique design

Unlike traditional brick-like power modules, ULIS uses a flat, octagonal design that fits more semiconductor devices into a smaller, lighter package. Its innovative current routing maximizes magnetic flux cancellation, delivering clean, low-loss electrical output and ultrahigh efficiency. This 2D structure exemplifies how thoughtful product design and development can balance performance and cost, while creating a high-performing module that is easier and more efficient to manufacture.

• Innovative fabrication

ULIS achieves high performance through a novel design that replaces traditional ceramic with a flexible polymer film. Unlike brittle ceramic, the 25-micron-thick film can be easily cut, shaped, and assembled with common tools while enduring extreme thermal cycling. Its adaptable structure allows lighter, thinner, and more configurable modules. Rigorous material composition analysis enabled faster, lower-cost production without sacrificing performance.

• Wireless function

A key advancement in ULIS allows it to operate wirelessly as a self-contained unit, controlled and monitored without external cables. Its interlocking, plug-and-play design enables seamless integration into a wide range of systems. This wireless capability supports real-time monitoring and control, helping improve operational efficiency across diverse applications. A low-latency communication protocol underpins the design, with a patent currently pending.

• Supporting sustainability

ULIS helps promote sustainability by using its ultra‑efficient design to convert more of the same electricity into usable power, reducing wasted energy and lowering overall consumption. Its high energy density means equipment can be smaller and lighter while using less electricity, which can ease pressure on power systems and reduce environmental impact. By squeezing more power out of existing supplies, ULIS supports more sustainable energy use.

(Also read: The Rise of Sustainable Automaking)

• Scalability

While silicon carbide semiconductors represent cutting-edge technology today, ULIS is designed to be future-ready, capable of integrating next-generation materials as they emerge. The module can scale to incorporate next-generation semiconductor materials, including silicon carbide improvements, gallium nitride, and even gallium oxide, which is still in early development. This adaptable architecture ensures ULIS can evolve alongside emerging technologies, maintaining high performance and efficiency while preparing for innovations that have yet to be commercialized.

ULIS Applications Across Energy and Transportation

ULIS is poised to make significant contributions across multiple sectors, from transportation to energy infrastructure. Its high efficiency and compact design could modernize electricity distribution, helping to deliver more usable power to homes, businesses, and industrial facilities. 

By switching electrical current rapidly and operating reliably at high temperatures, ULIS may reduce maintenance costs and extend the lifespan of power conversion systems, offering a smarter, more cost-effective alternative to traditional low-frequency transformers.

ULIS also has the potential to revolutionize advanced aviation. Its ability to transfer electricity faster and with minimal energy loss supports the creation of compact, lightweight, and high-performance power converters for next-generation aircraft. This includes emerging electric vertical takeoff and landing (eVTOL) vehicles, often called “air taxis,” where efficiency and affordability are crucial for commercial deployment. By enabling smaller, more efficient power systems, ULIS helps aircraft designers push the boundaries of both performance and sustainability.

Looking further ahead, ULIS could play a role in powering cities and data centers through next-generation fusion energy. Although commercial fusion remains a long-term goal, its deployment in areas where conventional infrastructure is difficult or expensive could be transformative. The module’s ultralow inductance, compact footprint, and dependable operation make it well-suited for the pulsed power components required in fusion systems, potentially accelerating the path toward scalable, clean energy solutions.

Across these applications, ULIS demonstrates the versatility and innovation needed to support evolving energy and transportation technologies. Its combination of efficiency, compactness, and reliability positions it as a powerful enabler in the renewable energy market, helping both established and emerging systems achieve higher performance while reducing environmental and operational costs.

Powering Tomorrow’s Innovation

ULIS is redefining how systems operate efficiently and sustainably. Its compact, high-performance design allows engineers to develop lighter, more resilient equipment while reducing energy waste and operational costs.

With scalable architecture, wireless functionality, and robust materials, ULIS supports both current and emerging technologies. By combining efficiency, reliability, and adaptability, it enables industries to meet growing energy demands and tackle environmental challenges.

ULIS demonstrates how cutting-edge power solutions can drive innovation, unlock new possibilities, and pave the way for a cleaner, smarter, and more versatile energy landscape.

 

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