Hillcrest Energy Technologies Unveils Technical Paper on Over 99% Efficient Single-Stage ZVS Power Architecture for 800V AI Data Centers

Technical Paper Tackles Safety in 800V Data Center Power Transition

The industry-wide shift from 400V AC to 800V DC power systems in AI data centers is gaining momentum, with the Open Compute Project (OCP) spearheading standardization efforts. Hillcrest's newly published technical paper, "Simplified 800V Power Supply Architecture for 99%+ Efficient Data Centers," addresses a critical challenge: simplifying power conversion architecture without sacrificing electrical safety.

The paper contrasts the prevalent complex two-stage designs with a simpler single-stage alternative based on Hillcrest's proprietary ZVS technology. A key industry concern with single-stage designs is the elimination of a conversion stage that traditionally ensures electrical isolation and fault containment. Hillcrest's design maintains both required galvanic isolation barriers—one at the medium-voltage transformer and another at the IT rack—while incorporating dedicated fault-management functions to replace the protective role of the removed stage. Simulation results demonstrate that this approach delivers higher efficiency than conventional two-stage systems.

Enhanced Efficiency and Reduced Complexity with Single-Stage Architecture

Hillcrest's technical findings reveal significant performance improvements over traditional two-stage 800V designs. The single-stage ZVS architecture achieves approximately 99% AC-DC conversion efficiency, with simulations indicating up to 99.2%, compared to 98% for two-stage designs. This improvement of over one percentage point at the power conversion stage could yield substantial energy savings in large-scale data center deployments.

In addition to efficiency gains, the single-stage design reduces component count by eliminating the intermediate 800V-to-800V isolated DC-DC conversion stage. This reduction is associated with enhanced reliability and lower cooling demands—critical factors for the economics and continuous operation of data centers. For operators, decreased cooling requirements translate into direct reductions in capital expenditures and ongoing energy costs.

ZVS Technology Advantages in the PCS1000 Prototype

The ZVS PCS1000 prototype power supply unit builds on the validated single-stage architecture, incorporating the benefits of Hillcrest's proprietary zero-voltage-switching topology. The PCS1000 captures both the efficiency and simplicity of single-stage conversion and the unique advantages of ZVS implementation.

Hillcrest's ZVS technology enables the PCS1000 to operate at a 48 kilohertz (kHz) switching frequency—approximately four times higher than conventional hard-switched converters—without incurring the typical switching losses. This higher frequency, combined with ZVS controls, reduces electromagnetic interference (EMI) compared to hard-switched designs, simplifying input filter requirements and easing compliance with grid and electromagnetic compatibility (EMC) standards. Additionally, reduced switching losses lower junction temperatures and thermal cycling in power semiconductors, enhancing reliability and lifespan essential for continuous data center operation.

Modular, Scalable Design for Data Center Deployment

The ZVS PCS1000 is designed as a prototype power supply unit specifically for 800V data center sidecar power racks. It converts 400/480V AC facility power directly to 800V DC in a single stage, eliminating intermediate transformation steps and aligning with the efficiency and simplicity benefits outlined in the technical paper.

The PCS1000 supports modular, N+1 redundant deployment, enabling system scaling from single units to multi-megawatt sidecar configurations that power high-density AI compute pods. This modularity offers flexibility for data center operators implementing the technology across various infrastructure scales. The PCS1000 remains in the prototype phase, with further development and validation ongoing.

Industry Context: OCP Standards and 800V Power Shift

The transition to 800V DC power systems in AI data centers marks a significant evolution in infrastructure standards. The Open Compute Project leads the standardization and pilot initiatives for this shift. As the standardization is still nascent, companies like Hillcrest have the opportunity to establish strong technology positions within this emerging ecosystem.

Higher-voltage DC systems provide inherent efficiency advantages over lower-voltage AC alternatives by reducing transmission losses and enabling smaller conductors and connectors. For AI data centers consuming tens of megawatts, these efficiency gains accumulate across numerous power conversion units. Hillcrest's technical paper contributes to industry discussions by proving that simplified, single-stage architectures can meet efficiency and safety standards necessary for broad adoption, potentially accelerating the transition timeline.

Engineering Leadership on Single-Stage Innovation

Emanuel Serban, Vice President of Engineering at Hillcrest, emphasized the company's differentiation strategy in the announcement. He noted that while the technical paper validates the single-stage approach on its own merits, the PCS1000 distinguishes itself by implementing this approach with Hillcrest's proprietary ZVS technology, combining single-stage conversion benefits with advantages in switching frequency, EMI reduction, and reliability.

Serban highlighted the PCS1000 platform's versatility, suitable for a wide range of DC electrification applications beyond data centers, including energy storage, microgrids, and electric vehicle powertrains, as outlined in Hillcrest's corporate profile. This broad applicability indicates the company views the technology validation as a foundation for multiple market opportunities.

Investor Marketing Partnership with Outside the Box Capital Inc.

On July 20, 2026, Hillcrest announced retaining Outside the Box Capital Inc. to provide investor marketing and distribution services. Based in Oakville, Ontario, the firm will disseminate information about Hillcrest across social media and community platforms such as Reddit, Discord, Telegram, and Twitter. Jason Coles, CEO of Outside the Box Capital Inc., leads these marketing efforts.

The engagement spans from July 20, 2026, through September 30, 2026, with Hillcrest agreeing to pay $50,000 plus applicable taxes. The announcement confirms that Outside the Box Capital Inc. operates at arm's length from Hillcrest, ensuring compliance with regulatory independence standards. This marketing initiative underscores Hillcrest's focus on enhancing investor awareness and community engagement amid advancing technical validation and prototype development.

Hillcrest's Technology Portfolio and Market Strategy

Hillcrest Energy Technologies Ltd. is a Canadian clean technology firm developing advanced power conversion technologies and digital control systems for next-generation energy applications. Its core proprietary zero-voltage-switching (ZVS) technology has been independently validated at global automotive OEM and Tier One supplier facilities, lending credibility to its technical claims and demonstrating prior commercialization pathways.

The company's technology spans multiple sectors: AI data centers (the current focus), energy storage, microgrids, and electric vehicle powertrains. This diversified approach positions Hillcrest's ZVS platform as a foundational technology across the broader electrification landscape rather than limiting it to a single market. The technical paper on 800V data center architecture reflects a targeted effort to establish thought leadership in the high-growth AI infrastructure segment.

Forward-Looking Statements and Risk Factors

The announcement contains forward-looking statements regarding the PCS1000's features, capabilities, and potential data center deployment. These statements are based on current expectations and assumptions and are subject to risks, uncertainties, and factors that could cause actual results to differ materially. Hillcrest emphasizes that no assurance exists that assumptions underlying these statements will prove accurate.

Readers should consider risks detailed in Hillcrest's disclosure record, including regulatory approvals, financing, political and regulatory challenges, stock exchange listing maintenance, and other business uncertainties. The company disclaims any obligation to update forward-looking statements except as required by law. Additional risk information is available in Hillcrest's continuous disclosure documents on SEDAR+ at www.sedarplus.ca. Investors are advised to review these materials and consult financial and technical advisors before making investment decisions.