Power electronics for next-generation electric vehicles

Standardised, highly compact, and cost-efficient power electronics to boost future electric vehicles and Europe’s e-mobility industry.

Europe’s ambitious goal to phase out new combustion-engine car sales by 2035 demands rapid innovation in electric vehicle (EV) technology. Key to this shift is improving the efficiency, reliability, and cost-effectiveness of power electronics, i.e., the systems converting electricity to drive EV motors and recharge their batteries. To strengthen Europe’s competitiveness and reduce reliance on external technology, the EU-funded SCAPE project (Switching-Cell-Array-Based Power Electronics Conversion for Future Electric Vehicles) is pioneering an innovative design approach to EV power converters. Coordinated by the Catalonia Institute for Energy Research (IREC), SCAPE (Grant No. 101056781, duration 2022–2026) introduces a standardised, modular, and scalable solution, directly addressing Europe’s electrification and industry leadership goals.

SCAPE targets groundbreaking key performance indicators: over 97.5% power conversion efficiency, a doubling of power density, and halving the cost per kilowatt compared to current standards. These advancements promise extended driving ranges, affordable EVs, and a strengthened European industry.
Modular and scalable power converters



SCAPE introduces a novel design approach with modular & scalable power converters based on multilevel neutral-point-clamped topologies. Its cornerstone is the switching cell, a standardised and compact basic building block, incorporating advanced power semiconductor technology and ancillary circuitry. Multiple switching cells interconnect to form ‘converter legs’, which then combine into complete power converters (Fig. 1). This modular approach enables flexible scaling, allowing the conception of power converters for small urban vehicles up to heavy-duty electric trucks from a single switching cell design, following standardised powertrain design rules, and leveraging on scale economies and low engineering effort for a potential manufacturing cost reduction.

The standardised design significantly reduces engineering complexity and cost. EV OEMs can now build customised converters efficiently, employing standardised modules produced at scale for a broad vehicle diversity.

SCAPE also proposes the integration of a traction inverter and an on-board charger into a single unit, leveraging a multiphase electric machine. This simplifies the vehicle design and manufacturing and greatly increases the powertrain capacity, reduces its cost, and increases its reliability through fault tolerance.
Chip-embedding integration technology

At the core of SCAPE’s innovation is the chip-embedding technology, placing power semiconductor chips directly inside the printed circuit board (PCB). Traditional power converters rely on separate, surface-mounted components, resulting in increased size, reduced switching speed, greater losses, and thermal limitations. SCAPE’s embedded approach substantially reduces stray inductance and enhances thermal management, boosting efficiency and power density. SCAPE has developed a first batch of chip-embedded switching cells (Fig. 2). Experimental validations confirm successful operation at demanding conditions and demonstrate a 45% reduction of junction-to-heatsink thermal resistance and an 85% reduction of the power-loop stray inductance, compared to a conventional implementation with discrete power devices in TO-247 packaging. Thus, chip-embedding not only shrinks the converter’s size but also enhances electrical and thermal performance and reliability, allowing for greater switching frequencies that further reduce the size of the converter capacitors and magnetic components, as well as the electromagnetic emissions.
Intelligent controls and predictive maintenance

SCAPE’s innovations extend to advanced controls and predictive health management (PHM) strategies. A powertrain digital twin – an exact virtual replica of the physical system – runs in parallel with the powertrain operation, processing data from an online monitoring system (OMS) to continuously assess the system state-of-health (SoH). PHM actions encompass predictive maintenance warnings and load redistribution among the switching cells, converter leg, and battery modules to maintain operation until servicing. Worth mentioning is the capability of the OMS to perform online measurements of the battery module’s internal impedance, a parameter directly linked to the battery’s SoH. The PHM proactive approach dramatically improves reliability, reduces downtime, and enhances user confidence in electric vehicles.
Expected impact

SCAPE aligns closely with European Commission objectives, contributing significantly to transportation decarbonisation and industrial resilience. By increasing powertrain efficiency, the project helps extend EV driving range, reduce battery size, and lower vehicle costs. Cost-effective power electronics directly translate into more affordable EVs, accelerating consumer adoption.

Moreover, SCAPE fosters European technological sovereignty. By standardising the switching-cell technology, the project supports the development of a robust, EU-based supply chain, minimising dependence on imported components and expertise. The innovative modular design enables rapid adaptation across vehicle classes, creating economies of scale within the European market.

The project’s predictive maintenance capabilities further enhance lifecycle sustainability, reducing electronic waste and improving environmental performance. SCAPE’s holistic approach thus ensures that Europe’s EV transition is technologically advanced, economically viable, and environmentally responsible.

Through strategic innovation and European collaboration led by IREC, SCAPE demonstrates how targeted research can yield practical solutions for a greener, more competitive automotive future.

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