Megawatt Charging Expands: Magnetics Face High Voltage, Frequency and Thermal Cycling

New high-voltage, high-frequency and thermal requirements for magnetics in megawatt charging systems.

IEA charging analysis shows continued expansion of fast and ultra-fast infrastructure, while 1,000 V vehicle platforms and megawatt-class charging bring much higher power into passenger and commercial-vehicle applications. Shorter charge times require upgrades across rectification, isolated DC/DC conversion, filtering and thermal management. Combined stresses on magnetics Transformers and inductors must operate under high voltage, high current, high switching frequency and repeated load transients. Core loss, copper loss, air-gap fringing, insulation aging and thermal cycling interact, so a single rated-point efficiency value is not enough to predict service life. Modularity matters Parallel power modules can improve serviceability and part-load efficiency. Magnetic components need consistent inductance, loss and temperature distribution, plus clear mechanical interfaces for cold plates, airflow and insulation structures. Source: IEA Global EV Outlook 2026 — Charging