Porsche and Bosch unveil a 720 kW electric drive inverter breakthrough
Porsche, Bosch, and the Fraunhofer Institute for Reliability and Microintegration (IZM) have teamed up to develop a cutting-edge electric drive inverter. The new device promises a major leap in performance for electric vehicles, delivering up to 720 kW of continuous power. This breakthrough comes as part of the Dauerpower project, which focuses on improving cooling and efficiency in high-power converters. The core challenge in electric vehicle drivetrains has long been managing heat. Overheating components can drastically cut performance, making thermal efficiency a key factor in design. The new inverter tackles this by using advanced materials and manufacturing techniques to boost power output by 20 to 30 percent over traditional silicon-based systems.
Central to the design are modern silicon carbide (SiC) transistors, which offer better efficiency and higher temperature resistance than standard silicon. Two of these transistors are mounted directly onto a ceramic substrate in a pre-packaging step, allowing flexible integration into circuit boards. This approach also improves modularity, making it easier to replace or repair individual sub-modules. Cooling plays a crucial role in the inverter's performance. For the first time, copper cooling elements are produced using 3D printing, combining the metal's superior thermal conductivity with the precision of additive manufacturing. This innovation helps maintain stable temperatures even under heavy loads, ensuring consistent power delivery. The prototype inverter achieves a continuous output of 720 kW (979 hp) with a rated current of 900 A. Such figures place it among the most powerful inverters developed for electric vehicles, addressing a critical need for high-performance drivetrains.
The collaboration between Porsche, Bosch, and Fraunhofer IZM has resulted in a prototype inverter with significant advantages in power, cooling, and modularity. By integrating silicon carbide technology and 3D-printed copper cooling, the design sets a new benchmark for electric vehicle efficiency. Further development will determine its eventual application in production models.
