Cooling Tech Becomes the Key to Next-Generation Fast Charging

As the global EV market accelerates, charging networks are entering a new phase of high-power deployment. Yet behind rising charging speeds and upgraded infrastructure, one technical element has quietly become essential: cooling technology.

Today, cooling performance directly shapes how fast, how stable, and how reliably EV chargers operate — especially as power levels move beyond 120 kW.

Cooling Defines Charger Performance More Than Ever

Modern public charging stations operate under intensive conditions: long operating hours, high user turnover, and growing demand for 180–350 kW ultra-fast charging.

These factors significantly increase the thermal load on power modules and charging cables.

Studies from operators show that insufficient cooling can lead to:

• Chargers running below rated output
• Higher failure and downtime rates
• Faster component aging and costlier maintenance

In this new era, thermal design is no longer secondary — it is central to charger reliability.

Industry Shift: From Basic Cooling to Thermal Engineering

As charging speeds rise, cooling technologies are evolving in three major directions:

1. Scalable Cooling for Charging Hubs

High-power hubs now require cooling systems that adapt to multi-vehicle operation and fluctuating loads. The traditional “one cooling system per charger” model is becoming obsolete.

2. Liquid-Cooled Cables for Ultra-Fast Charging

To reach 500A–600A current levels safely, liquid-cooled cables are quickly becoming standard. They are essential for unlocking true 350–600 kW charging performance.

3. Liquid-Cooled Power Cabinets

To keep sustained output during peak demand, liquid-cooled main cabinets provide stable operation and reduced derating — a critical requirement for the next generation of EV platforms.

These developments reflect a shift toward integrated cooling ecosystems, not just cooling components.

How FES Power Builds for the Cooling-Centric Future

With the market moving toward high-performance thermal management, FES Power has aligned its product strategy accordingly.

🔗 www.fescharging.com

Air-Cooled DC Fast Chargers (30–120 kW)

Designed for urban and commercial use, optimized airflow ensures stable performance even under continuous operation.

Liquid-Cooled Ultra-Fast DC Systems (180 kW+)

Built for expressways and high-demand charging hubs, delivering consistent high-power output for modern 800V EV platforms.

Liquid-Cooled Cable Options for 500A+ Applications

Supporting high-current ultra-fast charging scenarios where thermal control directly affects safety and speed.

Through these solutions, FES Power integrates cooling as a core engineering priority, positioning itself at the forefront of future EV charging infrastructure.