DC/DC Converters for Safety-Critical High-Performance Applications
DC/DC Converters as an Integral Part of the System Architecture
DC/DC converters are critical to the stability of the entire system.
Treating them in isolation leads to instability, EMC (electromagnetic compatibility) issues, thermal derating, increased integration effort, and costly redesigns in later project phases.
Silver Atena develops custom DC/DC converters as an integral part of the power architecture and power electronics. We support the entire development process – from system design and hardware to embedded software, verification, validation, and series production.
This results in robust solutions for complex and safety-critical applications in Automotive, Aerospace, and Defence.
In modern energy systems, different voltage levels such as 12 V, 48 V, 400 V, or 800 V must interact reliably. The DC/DC converter plays a central role by significantly influencing system stability, efficiency, EMC performance, thermal robustness, functional safety, and overall integration effort.
What may appear simple in a block diagram quickly becomes challenging under load steps, transients, and real operating conditions.
In many cases, the most critical issues do not arise within the converter itself, but at its interfaces within the power electronics and the overall system.
What is a DC/DC Converter?
A DC/DC converter is a power electronic system used to convert electrical energy between different DC voltage levels.
It ensures a stable and controlled power supply even under fluctuating input voltages, dynamic load conditions, and critical operating states – making it a key element of the energy architecture in modern systems.
Technically, the conversion is based on fast-switching semiconductors such as silicon carbide (SiC) or gallium nitride (GaN).
Depending on the application, different topologies are used:
- Buck (step-down) – e.g. from 400 V / 800 V to 12 V / 48 V
- Boost (step-up) – e.g. to support higher DC link voltages or charging requirements
- Galvanic isolation or direct coupling (isolated / non-isolated) – depending on requirements for safety, EMC robustness, and system integration
- Bidirectional energy flow – enabling power transfer in both directions, e.g. between battery, energy storage, and onboard network
In safety-critical high-performance applications, the DC/DC converter is not a peripheral component, but a central element of the power electronics.
It stabilizes the energy supply, regulates voltage and current in real time, and ensures the reliable interaction of all subsystems.
Without a properly designed DC/DC solution, system stability under real operating conditions cannot be ensured.
Why DC/DC Converters are Critical to the Overall System
In many development projects, DC/DC converters are considered as isolated components – this is where most problems originate.
Typical consequences in real-world applications include:
- EMC disturbances within the system
- unstable control behavior during load changes and transients
- thermal derating under continuous load
- integration issues between high-voltage and low-voltage domains
- design gaps that only become visible under worst-case scenarios, aging effects, or real load profiles
- delays in release, validation, and industrialization
These effects lead not only to technical deviations but also to increased costs, project delays, and additional development iterations – often resulting in complex redesigns.
Design issues in the converter do not remain local – they propagate throughout the entire system.
Custom DC/DC Converters for Automotive, Aerospace and Defence
Silver Atena develops DC/DC converters for applications where different voltage levels must operate together reliably, efficiently, and safely under real operating conditions.
The key factor is not only the electrical design, but above all the seamless integration into the system architecture, the ability to handle dynamic load conditions, and the consistent consideration of EMC, thermal behavior, and functional safety.
This is where the greatest risks arise – and where Silver Atena delivers.
Automotive
DC/DC converters enable the reliable coupling of high-voltage and low-voltage onboard networks and ensure a stable power supply – even under dynamic load conditions.
Silver Atena brings extensive experience in complex vehicle architectures, functional safety (ISO 26262), and validation under real load profiles – from concept phase through to series production.
Aerospace
DC/DC converters ensure the reliable power supply of avionics, actuators, and sensor systems – while meeting strict requirements in terms of weight, robustness, and reliability.
Silver Atena develops systems in accordance with rigorous certification standards (DO-254, DO-178C), with a strong focus on reliability, redundancy, and verified functionality under extreme operating conditions.
Defence
DC/DC converters ensure a reliable power supply for safety-critical systems – even under harsh environmental conditions and demanding operating conditions.
Silver Atena develops robust, mission-critical power electronics with high EMC robustness, stable operation under extreme conditions, and reliable integration into complex system architectures.
Application Examples from Real-World Projects
High-Voltage DC/DC Converter for Fuel Cell Vehicles
Development of a scalable high-performance converter for 400 V and 800 V systems with efficiencies above 98% and power levels up to 500 kW.
Designed for dynamic load conditions, high efficiency, and stable integration into complex vehicle architectures.
Electric Power Take-Off (ePTO)
Development of an isolated, bidirectional DC/DC system enabling energy transfer in both directions, with efficiencies above 94%.
Used for flexible energy distribution between battery, auxiliary drive, and onboard network in real high-voltage applications.
DC Boost Charger
Development of a high power density DC boost charger for efficient voltage level increase in charging and energy systems.
Designed for dynamic load requirements, fast control response, and robust integration into existing system architectures.
This demonstrates that Silver Atena develops solutions that operate reliably under real operating conditions and are ready for validation and release.
Technological Expertise and System Responsibility in Converter Development
The development of DC/DC converters requires deep expertise in power electronics and system engineering – from topologies and semiconductors to control, software, thermal design, EMC, and functional safety.
Many suppliers deliver a converter. Silver Atena takes system responsibility.
The difference lies in a holistic system understanding and the consistent integration into the power architecture.
Engineering Expertise from a Single Source
Silver Atena integrates all relevant disciplines early in the development process:
- System architecture – selection of suitable topologies and stable integration into the overall system
- Power electronics – robust power paths using advanced technologies such as SiC and GaN
- Control and software – stable algorithms for dynamic load conditions and transients
- Thermal design – efficient cooling for continuous operation, efficiency, and lifetime
- EMC – early consideration of electromagnetic requirements within the design process
- Functional safety – development in accordance with standards such as ISO 26262, DO-254, and DO-178C
Silver Atena combines deep engineering expertise with proven series production capability – from initial architecture decisions to validated and industrializable solutions.
Development Along the V-Model
Silver Atena develops DC/DC converters in accordance with the V-model – from system definition and topology selection to hardware and software development, through to series production.
Critical operating conditions such as load steps and transients are simulated and validated at an early stage. Verification and validation are carried out under real operating conditions before industrialization.
Result: robust, production-ready DC/DC converters.
Your Advantage: Reduced Project Risk and Increased Technical Reliability
A system-oriented development approach not only reduces technical risks, but also improves the predictability of the entire project.
Technical Benefits
- Reduced integration risks through early alignment of all subsystems
- Stable thermal design even under real continuous load conditions
- Fewer EMC issues through EMC-compliant design from the outset
- Robust control under dynamic load conditions and transients
- Reliable series production capability and high system stability
Economic Benefits
- Lower project costs due to fewer development iterations
- Shorter time-to-market
- Reduced risk of field failures
- Fewer redesigns in later project phases
- Increased confidence in release and industrialization processes
Result: predictable projects, stable approvals, and reliable systems in operation.
Who Silver Atena Is the Right Partner For
Silver Atena is the right partner if you consider DC/DC converters a critical part of your system architecture.
This is particularly relevant if you:
- are developing a custom DC/DC converter for a demanding application
- need to safely and efficiently couple high-voltage and low-voltage systems
- require early clarity on architecture, topology, and integration risks
- want to systematically address EMC, thermal design, control, and functional safety from the outset
- are looking for a partner that combines system expertise with series production capability
Silver Atena develops DC/DC converters as part of the power architecture – with close integration of all relevant disciplines and a continuous development process from system architecture through hardware and embedded software to testing, validation, and series production.
Experience from automotive, aerospace, and defence directly feeds into development.
The difference lies in system understanding.
Schedule an Initial Technical Consultation for DC/DC Converters
Are you planning to develop a DC/DC converter?
We support you in developing robust converter solutions for automotive, aerospace, and defence – with deep technical expertise, full system responsibility, and extensive experience in safety-critical high-performance applications.