The U.S. Department of Energy (DOE) has selected the National Renewable Energy Laboratory (NREL) to spearhead a new research initiative aimed at developing advanced materials and manufacturing techniques for power electronics. The newly established Center for Power Electronics Materials and Manufacturing Exploration (APEX) will be located at NREL’s facility in Golden, Colorado, and is designed to centralize efforts to boost the efficiency and scalability of essential components for the power grid, electric vehicles, and industrial applications.
According to NREL, the APEX facility is poised to support substantial thermal and power loads necessary to accommodate the increasing energy demands associated with next-generation power electronics and infrastructure.
Rising Demand for Advanced Power Electronics
The demand for innovative technologies such as artificial intelligence, autonomous electric vehicles, quantum computing, and Internet of Things (IoT) devices is surging. A report from the Semiconductor Industry Association indicates a 15% increase in demand within the automotive sector last year alone. In 2023, nearly one trillion semiconductors were sold globally, with analysts predicting sustained growth.
To meet this rising demand, APEX will focus on enhancing the diversity of materials available for substrates, ultrawide bandgap semiconductors, thermal sinks, and electrical contacts. NREL highlights promising materials such as borides, nitrides, carbides, and oxides, which can facilitate the creation of smaller yet more powerful devices. The center will also investigate methods to optimize material interfaces, critical to device performance.
Addressing Research Gaps in Advanced Manufacturing
While NREL has not disclosed specific research projects underway, the DOE has released a technical report identifying essential research areas in advanced manufacturing. The report emphasizes that technical advancements often begin with interface properties, which are crucial for synthesizing and integrating materials in electronic devices.
Surface chemistry is vital for scaling the production of components. Innovations in selective material growth and the atomic-level modulation of surface phases can lead to the development of new catalysts and materials for energy storage and conversion. Furthermore, surface design is integral to the manufacturing of energy systems such as catalysts and membranes, allowing precise nanoscale control over particle arrangements.
Researchers are exploring novel techniques to manipulate surface chemistry, including laser patterning methods. Recently, an NREL team unveiled a new laser technology aimed at enhancing electrode microstructures, improving electric vehicle charging performance.
Focus on Scalable Manufacturing Techniques
APEX will pursue four primary goals:
Streamlining substrates for power electronics interface designs.
Developing high-temperature, high-power synthesis processes to enhance efficiency.
Enabling faster, scalable manufacturing through hydride vapor phase epitaxy (HVPE) with increased growth rates.
Mitigating interface degradation.
The DOE has awarded NREL a $13.9 million grant to support this four-year initiative. This project is part of a broader funding effort, with the DOE allocating $118 million to various national laboratories and universities for energy research.
In collaboration with multiple partners, including Argonne National Laboratory in Illinois, Morgan State University, Johns Hopkins University in Maryland, the University of Virginia, and the Colorado School of Mines, NREL will also work alongside Kyma Technologies, a North Carolina-based company with prior experience in designing dynamic HVPE systems.
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