Bridging the power gap between 48V and 12V systems

To support this transition, Vicor has introduced a new family of high-density DC-DC converters – the DCM3717 & DCM3735 – designed to efficiently convert 48V to 12V while preserving legacy investments and enabling cutting-edge power performance. Speaking to Electronic Specifier, Maury Wood, Vice President of Strategic Marketing and Business Unit Operations at Vicor, outlined how these new modules are poised to support the next generations of industrial applications.

Why 48V?

“48V power architectures can deliver the same power level as 12V architectures using lower current, which dissipates less heat in wire harnesses and bus bars,” Wood explained. “Alternatively, a 48V system can deliver a much higher overall power level within the thermal budget established by an existing 12V system.”

The shift here is being driven by the increasing electrification of industrial equipment – such as high-capacity motors, actuators, and sensors – and by the growing intelligence of systems using embedded AI processors, cameras, and controllers. “The need for additional system power is increasing significantly,” he added.

Figure 1 - Power demands in automotive have steadily progressed since the 1900s. The gradual increase in power has required high voltage to be standardised and bussed to accommodate new loads. Today 48V is being adopted to support unprecedented power demands.

The new DCM family

The new DCM modules are non-isolated, regulated converters operating from a 40-60V input range and delivering a regulated 10-12.5V output. The DCM3717 is available in two versions – 750W and 1,000W – while the DCM3735 provides a 2,000W option. All come in a low-profile SM-ChiP surface-mount package measuring only 5.2mm thick, with a power density of 5kW/in³.

“These converters have a power density more than seven times higher than competitive DC-DC converters,” said Wood. “They allow engineers to transition to 48V and still use the cost-optimised 12V components, like fans for cooling electronic systems or enclosed cabin spaces.”

Bridging legacy and modern architectures

A significant motivation for developing these converters was the challenge posed by the entrenched 12V ecosystem. Many 12V components are highly cost-optimised due to decades of high-volume manufacturing. Rather than require a wholesale shift away from these components, Vicor’s new range of converters act as a bridge.

“The automotive industry has already adopted the concept of zonal power architecture,” Wood said. “In many cases, these zones still use 12V for cost and supply chain reasons. Industrial equipment is following this pattern – central 48V distribution with 12V zones – making efficient 48V-to-12V conversion essential.”

For applications such as battery formation and test (BFT) or semiconductor automated test equipment (ATE), the converters offer a path forward without discarding existing designs. “Some BFT systems were optimised for 12V and can’t be easily re-engineered for 48V. Our modules allow engineers to bridge these worlds,” he added.

Size and weight matter

Beyond bridging old and new systems, the DCM converters meet the strict form factor demands of emerging technologies.

“There are many industrial systems where size and weight are critical,” said Wood. “In battery-powered humanoid robots, for example, the form factor itself places significant constraints on volume. For airborne vehicles like delivery drones, minimal weight is essential.”

Figure 2 — Vicor DCM3717 and DCM3735, regulated 48V-12V converters ease the migration to 48V architectures

Handheld construction or medical tools also benefit from compact electronics. “In many cases, bulky discrete power systems have made it difficult to develop equipment to required specifications. Our modules support the continued trend toward miniaturisation in electronics.”

Thermally adept design

Thermal management remains one of the biggest challenges in power electronics, Vicor’s SM-ChiP package is engineered to try and simplify this as much as possible.

As Wood explained: “Both the mould compound and the gold surface plating used with SM-ChiP are thermally conductive. These modules are then, so active components like switching MOSFETs are close to the heat sink. The flat, coplanar form provides optimal thermal transfer.”

This design gives engineers greater freedom when creating thermal paths and managing heat dissipation – an often-critical consideration in high-performance or tightly packed systems.

Scalable and futureproof

Another key advantage of the new DCM family is its scalability. Engineers can parallel up to four DCMs to achieve up to 9kW of output power. “With just a few control signals between the modules, you get seamless current sharing,” said Wood. “You can design a single PCB layout to support 2, 4, 6, or 8kW by simply populating more modules.”

This flexibility not only simplifies system upgrades but also supports cost-effective prototyping and future expansion.

A complete 48V ecosystem

The DCM3717 and DCM3735 are part of Vicor’s broader 48V power strategy. They complement other Vicor offerings, such as the BCM fixed-ratio bus converters that step high-voltage sources (800V or 400V) down to 48V.

Figure 3 — Vicor is enabling easy conversion from high voltage to 12V via a 48V hub, not just for automotive but industries. 48V power architectures can deliver the same power level as 12V power architectures using lower current, which dissipates less heat energy in wire harnesses and bus bars.

“Once a 48V bus is established, our DCM products take over to efficiently convert to regulated 12V or lower voltages,” Wood noted. “We also offer point-of-load converters down to sub-1V, some with bidirectional operation and exceptional transient response – features that support new regenerative energy applications.”

Enabling modern industrial power delivery

As industrial systems continue to evolve in complexity and performance, the shift toward 48V power architectures reflects a broader effort to improve efficiency, reduce thermal losses, and meet growing energy demands. However, for many engineers, the reality of existing 12V infrastructure presents practical challenges when upgrading to higher-voltage systems.

Vicor’s DCM3717 and DCM3735 converters respond to this gap by offering a means to integrate 48V distribution while maintaining compatibility with 12V components. With compact form factors, efficient thermal performance, and the ability to scale output power, the converters are intended to support a variety of use cases – from robotics and drones to test equipment and industrial automation.

Rather than replacing existing systems outright, the approach enables incremental transitions to newer architectures, allowing engineers to adapt designs at a pace that aligns with both technical and commercial constraints. As 48V becomes more common in industrial applications, solutions that support this kind of flexibility are likely to play an important role in the next phase of power system design.