EV sales are projected to exceed 60% of total global car sales by 2035, which puts DC fast charging at the forefront of requirements rather than a luxury. The next frontier in the EV charging ecosystem is deploying 350 kW+ DC fast chargers, properly designed and installed, as that level of charge can give enough energy to achieve 200 – 300 km of range in 10-15 minutes, comparable to refuelling times of an internal combustion engine vehicle.

The Impact of 350 kW+ Chargers

Standard DC fast chargers (50-150 kW) have played an important role in the mainstream adoption of previous generations of EVs; however, the long-range EVs being produced today with high-performance and battery packs larger than 70-120 kWh require faster, higher-power charging to ensure a comparable level of long-distance convenience when taking trips. The introduction of 350 kW chargers has had far-reaching ramifications on the user experience:

Total charge times have been drastically reduced; the example of the Porsche Taycan (if you charged from 10-80%) on a 50-150 kW system would generally take 30-60 mins on most EVs, whereas its 800V capable battery and charging on a 350 kW system will reduce times down to 10-18 mins.

With better compatibility with future EVs, automakers going to 800V and even up to 900V architectures, these chargers will allow times and quicker connections as well as unlocking peak performance from vehicles. The Kia EV9 (800V), for example, from 10-80% with charging at 350 kW, will supply the vehicle with additional range in 18 minutes. The Lucid Air (924V) gets you approximately 300 miles in about 20 minutes with charge rates exceeding 300 kW.

Less congestion at charging stations: As they offer greater throughput with fast charge rates, more unique vehicles can be connected to installed charging stations each day, improving the Return on Investment (ROI) on developing infrastructure.

350kW+ DC Fast Charging—Technical Innovations

1. Higher Voltage Battery Platforms

400V battery packs are used by many legacy EVs, but charging at 350kW+ needs 800V-1000V systems to reduce current and provide higher power. Higher voltage accounts for less current for any power (P=V×I). The lower (smaller) current means reduced heat in all that thick cable (even though they tend to have a high temperature rating).

OEMs are switching to 800V charging systems quickly:

• Porsche Taycan: 800V, 270-350kW
• Hyundai e-GMP platform (Ioniq 5, EV6) – 800V battery
• The GM Ultium platform can go to 800V for future vehicles.  GM plans to go 800V for their future EVs.

2. Liquid-Cooled Cables & Connectors

Delivers 350 kW at 800 V which is up to 437 A of continuous current (P=V×I → 350,000 W/800 V=437.5 A). Air-cooled cables will overheat at >250 A, so they won’t work as intended. Liquid-cooled cables, as seen with an ABB Terra HP charger, keep the liquid under 50 °C (122°F) – safe and reliable.

• ABB Terra 360: liquid cooled, continuous power output of 360 kW, 4 simultaneous charging ports.

3. Advanced Power Electronics

Silicon carbide (SiC) MOSFETs and diodes are being accepted quickly, and replacing many silicon IGBTs in high-power chargers. SiC allows for:

• 98%+ conversion efficiency, thus less energy waste and heat.
  Smaller form factors: Delta Electronics reported SiC reduced the charger cabinet size by 30% compared to silicon.
• Increased durability and lower total cost of ownership (TCO) over the life of the charger.

4. Dynamic Load Management & Grid Connectivity

New 350 kW+ charging hubs have advanced software and systems for:

• Dynamic load management—the ability to distribute power to each vehicle in real time to optimize throughput for the station.
• Smart grid connection—the ability to enable demand response that allows chargers to ramp down during grid stress events or ramp up when grid demand is low.

An example of this dynamic load management is Tesla’s Supercharger V4 stations, which dynamically manage the power up to 615 kW total per cabinet and dynamically loads each stall with power as available.

Global Deployments 

Europe: Ionity

Ionity has more than 600 sites across 24 countries and only deploys 350 kW chargers using CCS Combo 2 connectors. An Ionity station typically has 4-6 chargers. The data shows Ionity’s average session duration has decreased from 24 minutes (2020) to 14 minutes (2024) with an estimated increase of 800V-capable EVs on the road.

USA: Electrify America

Electrify America has deployed >1500 350kW chargers programmed in major highway corridors. At the flagship Baker Superstation located on I-15 (Las Vegas-Los Angeles), the Baker Superstation has 8 – 350 kW chargers providing > 1000 charging sessions per week. Recently, Electrify America launched their advanced Power Routing Technology to dynamically route power between different chargers on the basis of each vehicle’s charging curve.

Grid & Infrastructure Challenges for DC Fast Charging

Powering high-power DC fast charging with grid power demands an incredible amount of capacity from the local grid. For example:

• A charging station with 4×350 kW chargers will require about 1.4 MW capacity, which is a similar capacity to a small factory.
• If we frequently deploy simultaneous charging efforts, it is possible that the station could cause voltage sags, and this may require substantial grid upgrades or major energy storage behind the meter.
  

To mitigate some of the above challenges, the BESS deployments and storage capacity within these systems for ultra-fast charging are becoming more common by operators within Europe:

• Shell Recharge has deployed a 360 kWh BESS at their London Fulham site, allowing for peak shaving using their technology, which allows them to store energy off the grid (off-peak) and draw that energy from the BESS to enable ultra-fast charging without stressing the grid during peak load.
  

Market Trends & Regulatory Support

• BloombergNEF forecast is that charger installations ≥350kW will grow at a compound annual growth rate (CAGR) of 47% from 2020-2024, with an anticipated global total of 65,000 public chargers ≥350 kW by 2030.
• Under the European Union’s Alternative Fuels Infrastructure Regulation (AFIR), at least one charger ≥350 kW will need to be available every 60 km on select TEN-T Core Network highways by 2025, allowing for ramp-up in installations.
• Automakers such as Mercedes-Benz, Stellantis, and BMW are co-investing into high-power networks. Mercedes-Benz and ChargePoint have a joint venture with MN8 to install over 2,500 350 kW stations by 2027 across North America.

Future Perspective

350 kW and beyond fast-charging technologies are at the verge of mass market adoption, or the inflexion point. Advances in:

• High-voltage EV architectures,
• SiC-based power electronics,
• Liquid-cooled cable technologies,
• Smart grid integration will allow ultra-fast charging to be equal to or even exceed the convenience of petrol refuelling and eliminate the final barrier for the general adoption of EVs.
  

Finulent Solutions is positioned to take the role of leadership in the transition with the design, engineering, and deployment of high-power EV charging infrastructure, ensuring a reliable, efficient, and seamless user experience.