Exicom Starts India Manufacturing of Liquid-Cooled EV Charger Power Modules

Exicom Begins Local Manufacturing of Liquid-Cooled Power Modules

Exicom has started manufacturing what it says are India’s first liquid-cooled power modules for EV chargers at its Hyderabad facility and has begun exporting the locally manufactured units to the United States. The company spent close to two years developing the technology and invested about $3.5 million in the project, according to Anshuman Divyanshu, CEO, EVSE, Exicom. The programme covered engineering, validation and the establishment of specialised manufacturing capability needed to produce the modules at scale. The development involved Exicom teams across India, Brisbane and the United States, while the modules are now being deployed in next-generation DC fast chargers and solar inverters for international markets.

Modules Developed for Higher-Efficiency Charging

The liquid-cooled modules have been developed to improve the efficiency and thermal performance of high-power charging systems. According to Divyanshu, the new modules can achieve efficiency of up to 99%, compared with approximately 95-96% for conventional modules. They use silicon carbide-based power electronics, which Exicom expects to become increasingly important as EV charging systems demand higher conversion efficiency. Liquid cooling allows the power electronics to operate within a more controlled temperature range while supporting greater power density. This becomes increasingly relevant as EV batteries accept higher charging rates and charging infrastructure moves towards higher currents.

Technology Linked to Tritium’s Charging Platform

Exicom gained access to liquid-cooled DC fast-charging technology following its acquisition of the business and assets of Tritium, the Australian charging technology company, in 2024. Exicom subsequently worked on developing next-generation liquid-cooled AC-DC and DC-DC modules for manufacturing in India. The company has now started exporting these modules from its Hyderabad facility to its factory in the United States. Divyanshu said rectifiers for next-generation chargers operating under the Tritium umbrella are being powered by the modules manufactured in Hyderabad, creating a direct connection between Exicom’s Indian power-electronics manufacturing capability and its international charging products.

Higher Cost Offset by Longer Operating Life

Liquid cooling currently comes with a substantially higher manufacturing cost than conventional air-cooled technology. Divyanshu said the bill-of-material cost of the new liquid-cooled modules is currently around twice that of conventional air-cooled modules, although Exicom expects the difference to narrow as production volumes increase. The company is offering a 10-year warranty on the liquid-cooled modules, compared with approximately two years typically associated with air-cooled modules, according to Divyanshu. Based on operating-life economics, he estimates that the liquid-cooled units could ultimately be around 25-30% cheaper on a total-cost-of-ownership basis while also delivering higher energy efficiency.

International Markets Expected to Lead Adoption

Despite manufacturing the technology in India, Exicom expects overseas markets to provide the larger immediate opportunity for liquid-cooled charging technology. Divyanshu said the United States and Europe are more mature high-power charging markets, where customers have a greater willingness to pay for higher-performance technology. Exicom expects its next-generation international products to use the liquid-cooled modules, while its Indian charger business is expected to remain overwhelmingly air-cooled in the near term. The company estimates that approximately 95% of its Indian charging applications will remain air-cooled and 5% liquid-cooled for at least the next two years.

India Expected to Shift Gradually Toward Liquid Cooling

Exicom expects the balance between air-cooled and liquid-cooled charging technology in India to begin changing over the next two to three years as vehicles capable of accepting higher charging currents enter the market. India’s high ambient temperatures could also strengthen the case for liquid cooling because conventional air-cooled power modules can derate at elevated temperatures to protect their components. This can reduce the charging power available to an EV. Divyanshu said liquid cooling can allow chargers to maintain performance even when ambient temperatures reach around 45 degrees Celsius, while maintaining an optimal module temperature can also support reliable operation in sub-zero conditions encountered in markets such as Europe and the United States.

Higher-Current Charging Drives the Technology Case

The technology becomes particularly relevant as charging systems move towards higher-current operation. Divyanshu said liquid cooling becomes necessary as charging currents move beyond around 500 amps and will be integral to Megawatt Charging System applications being developed for heavy-duty electric vehicles. Exicom is therefore developing a technology platform for demand that has not yet emerged at scale in India. The company expects faster-charging vehicles and higher-power infrastructure to eventually increase the relevance of liquid-cooled modules in the domestic market. Higher charging currents create greater thermal-management requirements, making the ability to control component temperatures an increasingly important consideration for future charging infrastructure.

Bidirectional Architecture Supports Future V2G Applications

The new modules are also bidirectional, according to Divyanshu, providing the hardware capability required for vehicle-to-grid applications. Bidirectional power conversion could enable electricity to flow between EVs and the grid when the wider energy ecosystem and regulations support such applications. However, the broader deployment of V2G in India will depend on the development of the electricity ecosystem and regulatory framework required to manage bidirectional power flows. Exicom’s decision to develop bidirectional modules therefore extends the technology beyond conventional one-way EV charging and creates a platform that could support additional energy-management applications as charging and grid-integration requirements evolve.

Power Electronics Platform Extends Beyond EV Chargers

The liquid-cooled module architecture is not restricted to EV charging applications. Exicom is also using the technology in solar inverters being piloted with customers in the United States, allowing the company to deploy the same power-electronics platform across multiple applications. This wider application potential could improve the utilisation of the technology as manufacturing volumes increase. It also provides Exicom with opportunities to apply its thermal-management and power-conversion capabilities beyond charging infrastructure. By combining applications across EV chargers and solar power systems, the company can potentially build greater production scale while continuing to refine the performance and economics of its liquid-cooled power-electronics architecture.

Exicom Plans to Retain the Technology Initially

For the time being, Exicom intends to keep the liquid-cooled modules largely captive for its own products despite receiving interest from other companies. Divyanshu described the technology as Exicom’s unique intellectual property and said the company plans to use it internally for the next few quarters. The approach allows Exicom to establish the modules as a differentiator within its own chargers and power-electronics products before potentially supplying the technology to third-party manufacturers. A later move towards external supply could create an additional business opportunity, but the company is currently prioritising its own product portfolio and the development of manufacturing scale.

Hyderabad Positioned as a Global Power-Electronics Base

Exicom is also working to reduce the cost of the liquid-cooled modules as production scales. Divyanshu expects higher shipments from India over the coming year to improve manufacturing economics, potentially narrowing the current cost gap with conventional air-cooled modules. The company is looking to establish Hyderabad as a production base for power electronics serving both domestic and global businesses. The start of exports marks an early step in that strategy, with locally manufactured modules already supporting international charging products. Over time, higher volumes, improved manufacturing efficiency and broader applications could strengthen the commercial case for liquid-cooled power electronics across EV charging and renewable-energy systems.

Frequently Asked Questions

What are Exicom’s liquid-cooled power modules used for?
Exicom’s liquid-cooled power modules are designed for high-power EV charging and other power-electronics applications requiring improved thermal management and conversion efficiency. The modules can achieve efficiency of up to 99% and are being used in next-generation DC fast chargers and solar inverters. They also have a bidirectional architecture that can support future vehicle-to-grid applications. Exicom is manufacturing the modules in Hyderabad and has begun exporting them to the United States, while expecting international markets to adopt the technology faster than India in the near term.