Guide Overview

Ultra-Fast EV Charging is accelerating the transition to electrified transportation by enabling rapid DC charging directly to electric vehicle batteries—delivering up to 1 megawatt of power for heavy-duty and long-range applications. This shift supports higher-voltage architectures (800V and above), reduces charging time to under 15 minutes, and helps meet global sustainability goals. Key enablers include silicon carbide (SiC) MOSFETs and integrated power modules that offer higher efficiency, thermal performance, and power density compared to legacy silicon technologies.

This System Solution Guide provides a comprehensive blueprint for designing high-power EV chargers. It explains the differences between AC and DC charging systems, outlines charger levels from 22 kW residential DC wallboxes to 350 kW+ ultra-fast commercial chargers, and introduces topologies such as Vienna Rectifier, Dual Active Bridge (DAB), and Flying Capacitor designs. It also covers bi-directional charging capabilities for vehicle-to-grid (V2G) applications and explores how photovoltaic (PV) and energy storage integration can stabilize local grids and reduce operational costs.

onsemi’s solution portfolio includes EliteSiC MOSFETs, Field Stop IGBTs, isolated gate drivers, and integrated power modules optimized for charger efficiency, scalability, and safety. The guide features interactive block diagrams, evaluation boards like the 25kW SEC-25KW-SIC-PIM-GEVK, and thermal-optimized module packaging. Designers will find product recommendations for every power level and reference tools to accelerate development of next-generation fast charging infrastructure.