The new IDTechEx report “Power Electronics for Electric Vehicles 2023-2033” provides a deep-dive into EV power electronics with technology insights into the evolving semiconductor and package materials, including Si, SiC and GaN semiconductors, die-attach materials, wire bonding, thermal management, and more. IDTechEx presents granular forecasts detailing unit sales, GW and US$ demand for inverters, onboard chargers (OBC) and DC-DC converters segmented by voltage (600V, 1200V) and semiconductor type (Si, SiC, GaN).

While Si IGBTs have dominated the medium-to-high power device range for 20 years, including in EV power electronics, they are giving way to a new generation of WBG materials: SiC and GaN. This will fundamentally impact the design of new power devices, including the package materials, as high voltage and high power-density modules operating at higher temperatures becomes the trend.

The two drivers often cited to move from 350-400V to 800V and beyond are higher power levels of DC fast charging (DCFC), for example, 350kW, and drive cycle efficiency gains. DCFC compatibility today is a relatively weak driver due to low availability versus AC chargers and the high costs associated with 800V infrastructure. Indeed, the IDTechEx report “Charging Infrastructure for Electric Vehicles and Fleets 2022-2032” estimates around 3 million AC charging installations took place in 2022, compared to ~50,000 DCFCs over 100kW. In addition, higher levels of DCFC does not necessarily drive a transition to 800V, although it is more optimal. Tesla is a good example, having deployed 250kW superchargers without moving beyond its 350V platform.

The efficiency argument for 800V is the stronger one. This allows joule losses to be reduced and high voltage cabling to be downsized. Combined with SiC MOSFETs, it typically leads to 5-10% efficiency gains, which can potentially downsize the expensive battery, save costs, or improve the vehicle’s range, creating a competitive advantage.

Yet, it is a challenging time for the automotive industry and 800V adoption experienced some pitfalls in 2022. The Lucid Air, the first 900V production car, sold around 7000 units in 2022 after an initial goal of 20,000. Porsche’s Taycan was also one of the OEM’s best-selling models in Europe between 2020 – 2021, but sales declined in 2022. Both are the results of continued parts shortages and supply chain challenges, for example, wire harness shortages with the Russia-Ukraine war.

On the other hand, Hyundai is demonstrating the success of 800V platforms. Sales of the company’s models using the 800V E-GMP platform more than doubled in South Korea to around 70,000 units/year, driven by the popularity of the IONIQ 5 and Kia EV6. This takes the 800V car market out of the luxury segment and predominantly into mainstream car segments for the first time. To support the rapid growth, Hyundai is diversifying its SiC supply partnerships, signing new deals with Onsemi and STMicroelectronics in 2022 to add to existing relationships with Infineon and Vitesco.