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Powering the AI Era: Innovations in Data Center Power Supply Design and Infrastructure

Recently, Data Center Frontier sister publication Electronic Design (ED) released an eBook curated by ED Senior Editor James Morra titled In the Age of AI, A New Playbook for Power Supply Design, with a collection of detailed technology articles focused on understanding the nuts and bolts of delivering power to AI-centric data centers. This compendium explores […]

Recently, Data Center Frontier sister publication Electronic Design (ED) released an eBook curated by ED Senior Editor James Morra titled In the Age of AI, A New Playbook for Power Supply Design, with a collection of detailed technology articles focused on understanding the nuts and bolts of delivering power to AI-centric data centers.

This compendium explores how the surge in artificial intelligence (AI) workloads is transforming data center power architectures and includes suggestions for addressing the issues.

Breaking the Power Barrier

As GPUs like NVIDIA’s Blackwell B100 and B200 cross the 1,000-watt threshold per chip, rack power densities are soaring beyond 100 kW, and in some projections, approaching 1 MW per rack. This unprecedented demand is exposing the limits of legacy 12-volt and 48-volt architectures, where inefficient conversion stages and high I²R losses drive up both energy waste and cooling load.

Powering the Next Era of AI Infrastructure

As AI data centers scale toward multi-megawatt clusters and rack densities approach one megawatt, traditional power architectures are straining under the load. The next frontier of efficiency lies in rethinking how electricity is distributed, converted, and protected inside the rack.

From high-voltage DC distribution to wide-bandgap semiconductors and intelligent eFuses, a new generation of technologies is reshaping power delivery for AI. The articles in this report drill down into five core themes driving that transformation:

Electronic Fuses (eFuses) for Power Protection

Texas Instruments and others are introducing 48-volt-rated eFuses that integrate current sensing, control, and switching into a single device. These allow hot-swapping of AI servers without dangerous inrush currents, enable intelligent fault detection, and can be paralleled to support rack loads exceeding 100 kW. The result: simplified PCB design, improved reliability, and robust support for AI’s steep and dynamic current requirements.

The Shift from 48 V to 400–800 V High-Voltage DC (HVDC)

Traditional 48-volt power distribution is approaching its physical limits. Delivering 600 kW at 48 V requires roughly 12,500 amps—necessitating bulky, liquid-cooled busbars. By contrast, 800-volt distribution reduces current to about 750 amps, enabling air-cooled operation and lighter, more economical infrastructure. Hyperscalers are piloting “sidecar” power racks that use HVDC distribution to free up server rack space for compute and minimize double-conversion inefficiencies.

Disaggregation of Power and Compute

Vicor and others argue that decoupling compute from power infrastructure—using ±400 V DC distribution and liquid-cooled busbars—enables far denser AI racks, reaching up to 720 PFLOPS per 48U rack. This disaggregated architecture aligns with broader industry trends toward liquid cooling, higher GPU density, and Open Compute Project (OCP) ORv3 high-power rack standards—key enablers of next-generation AI supercomputers.

Wide-Bandgap Semiconductors (SiC and GaN) in Power Supplies

Silicon carbide (SiC) and gallium nitride (GaN) are rapidly supplanting traditional silicon MOSFETs in server power supply units. These wide-bandgap materials deliver higher efficiency, faster switching, and superior thermal stability. SiC enables high-voltage conversion (1,000 V+), while GaN supports compact, high-frequency topologies in the 100–650 V range. Hybrid Si/SiC/GaN PSUs (3–12 kW modules) are already appearing in reference designs from Infineon, Analog Devices, and others.

Strategic Industry Implications

Sustainability and reliability are emerging as key differentiators for these power technologies. With AI data centers projected to consume up to 10% of global electricity by 2030, efficiency gains from HVDC and wide-bandgap semiconductors will directly influence operating costs and ESG performance.

Meanwhile, eFuse-based hot-swapping, predictive fault management, and intelligent current sharing will reduce downtime risks in hyperscale AI clusters. These advances—along with HVDC sidecars and liquid-cooled busbars—will reshape rack layouts, cabling standards, and thermal strategies. Such design implications must now be addressed early in the data center planning phase.

Early adopters—including Microsoft, Meta, Google, and Amazon—are already trialing HVDC and WBG implementations, signaling an impending wave of standardization across hyperscale ecosystems. As hyperscalers converge on these technologies, adoption among smaller AI data centers will become faster and easier.

Why This Matters for Data Center Frontier Readers

For hyperscale operators, colocation providers, and infrastructure investors, this report highlights a fundamental shift underway in data center power delivery. AI workloads are not only driving unprecedented total power demand: they’re redefining how power must be distributed and managed within the rack itself.

Traditional efficiency gains of 5–10% are no longer sufficient, and incremental improvements to legacy architectures amount to stopgaps at best. To meet the escalating power demands of AI-centric data centers, wholesale architectural redesigns are now in motion.

In short, the foundational changes the industry must prepare for include:

  • Transitioning to 400–800 V DC power distribution.

  • Adopting GaN- and SiC-enabled power supply units as standard.

  • Investing in liquid-cooled, high-density racks with disaggregated power infrastructure.

  • Leveraging intelligent eFuse protection for operational resilience and uptime.

Ultimately, the report underscores that power electronics are becoming as strategically important as compute silicon in defining the performance, economics, and sustainability of AI-era data centers.

Looking Ahead: The New Power Frontier

This evolution in power architecture is central to the story Data Center Frontier continues to track across its coverage of AI infrastructure, grid modernization, and energy strategy. From HVDC sidecars and modular power blocks to liquid-cooled server designs and reimagined utility interconnections, the industry is entering an era where electrical and mechanical systems are co-evolving with compute.

For DCF readers, understanding these converging forces is essential: not just to anticipate technology adoption curves, but to navigate where investment, policy, and design are heading in the race to power AI at scale.

 

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Chinese cyberspies target VMware vSphere for long-term persistence

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New Fortress Energy Seals Deal to Continue Supplying Gas to Puerto Rico

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BGN Plans Global Gas Push Ahead of New Supplies

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Crude Finishes Higher on Short Covering

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ITT Agrees to Buy Lone Star’s SPX Flow in $4.8B Deal

ITT Inc. has agreed to acquire industrial equipment manufacturer SPX Flow Inc. from Lone Star Funds in a $4.775 billion cash and stock deal. The deal will will consist of a combination of cash and $700 million in ITT common stock issued to Lone Star, according to a statement confirming an earlier report by Bloomberg News that the companies were nearing a deal. Charlotte, North Carolina-based SPX Flow makes products including valves and pumps under brands such as APV and Johnson Pump, as well as food processing equipment such as its Gerstenberg Schröder-branded butter maker. Lone Star Funds agreed in 2021 to take SPX Flow private for $3.8 billion including debt.  The SPX Flow acquisition is the largest ever by Stamford, Connecticut-based ITT, according to data compiled by Bloomberg. ITT’s shares have gained 28% this year, giving it a market value of $14.3 billion. ITT’s history dates to 1920, with its genesis as International Telephone and Telegraph, a provider of telephone switching equipment and services, according to the company’s website. In 1995, that conglomerate was split into three divisions, including the company that became the current manufacturer of components and technology for a range of transportation, industrial and energy markets. WHAT DO YOU THINK? Generated by readers, the comments included herein do not reflect the views and opinions of Rigzone. All comments are subject to editorial review. Off-topic, inappropriate or insulting comments will be removed.

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Energy Department Launches Breakthrough AI-Driven Biotechnology Platform at PNNL

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Chevron, Gorgon Partners OK $2B to Drill for More Gas

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At the Crossroads of AI and the Edge: Inside 1623 Farnam’s Rising Role as a Midwest Interconnection Powerhouse

That was the thread that carried through our recent conversation for the DCF Show podcast, where Severn walked through the role Farnam now plays in AI-driven networking, multi-cloud connectivity, and the resurgence of regional interconnection as a core part of U.S. digital infrastructure. Aggregation, Not Proximity: The Practical Edge Severn is clear-eyed about what makes the edge work and what doesn’t. The idea that real content delivery could aggregate at the base of cell towers, he noted, has never been realistic. The traffic simply isn’t there. Content goes where the network already concentrates, and the network concentrates where carriers, broadband providers, cloud onramps, and CDNs have amassed critical mass. In Farnam’s case, that density has grown steadily since the building changed hands in 2018. At the time an “underappreciated asset,” the facility has since become a meeting point for more than 40 broadband providers and over 60 carriers, with major content operators and hyperscale platforms routing traffic directly through its MMRs. That aggregation effect feeds on itself; as more carrier and content traffic converges, more participants anchor themselves to the hub, increasing its gravitational pull. Geography only reinforces that position. Located on the 41st parallel, the building sits at the historical shortest-distance path for early transcontinental fiber routes. It also lies at the crossroads of major east–west and north–south paths that have made Omaha a natural meeting point for backhaul routes and hyperscale expansions across the Midwest. AI and the New Interconnection Economy Perhaps the clearest sign of Farnam’s changing role is the sheer volume of fiber entering the building. More than 5,000 new strands are being brought into the property, with another 5,000 strands being added internally within the Meet-Me Rooms in 2025 alone. These are not incremental upgrades—they are hyperscale-grade expansions driven by the demands of AI traffic,

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Schneider Electric’s $2.3 Billion in AI Power and Cooling Deals Sends Message to Data Center Sector

When Schneider Electric emerged from its 2025 North American Innovation Summit in Las Vegas last week with nearly $2.3 billion in fresh U.S. data center commitments, it didn’t just notch a big sales win. It arguably put a stake in the ground about who controls the AI power-and-cooling stack over the rest of this decade. Within a single news cycle, Schneider announced: Together, the deals total about $2.27 billion in U.S. data center infrastructure, a number Schneider confirmed in background with multiple outlets and which Reuters highlighted as a bellwether for AI-driven demand.  For the AI data center ecosystem, these contracts function like early-stage fuel supply deals for the power and cooling systems that underpin the “AI factory.” Supply Capacity Agreements: Locking in the AI Supply Chain Significantly, both deals are structured as supply capacity agreements, not traditional one-off equipment purchase orders. Under the SCA model, Schneider is committing dedicated manufacturing lines and inventory to these customers, guaranteeing output of power and cooling systems over a multi-year horizon. In return, Switch and Digital Realty are providing Schneider with forecastable volume and visibility at the scale of gigawatt-class campus build-outs.  A Schneider spokesperson told Reuters that the two contracts are phased across 2025 and 2026, underscoring that this arrangement is about pipeline, as opposed to a one-time backlog spike.  That structure does three important things for the market: Signals confidence that AI demand is durable.You don’t ring-fence billions of dollars of factory output for two customers unless you’re highly confident the AI load curve runs beyond the current GPU cycle. Pre-allocates power & cooling the way the industry pre-allocated GPUs.Hyperscalers and neoclouds have already spent two years locking up Nvidia and AMD capacity. These SCAs suggest power trains and thermal systems are joining chips on the list of constrained strategic resources.

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The Data Center Power Squeeze: Mapping the Real Limits of AI-Scale Growth

As we all know, the data center industry is at a crossroads. As artificial intelligence reshapes the already insatiable digital landscape, the demand for computing power is surging at a pace that outstrips the growth of the US electric grid. As engines of the AI economy, an estimated 1,000 new data centers1 are needed to process, store, and analyze the vast datasets that run everything from generative models to autonomous systems. But this transformation comes with a steep price and the new defining criteria for real estate: power. Our appetite for electricity is now the single greatest constraint on our expansion, threatening to stall the very innovation we enable. In 2024, US data centers consumed roughly 4% of the nation’s total electricity, a figure that is projected to triple by 2030, reaching 12% or more.2 For AI-driven hyperscale facilities, the numbers are even more staggering. With the largest planned data centers requiring gigawatts of power, enough to supply entire cities, the cumulative demand from all data centers is expected to reach 134 gigawatts by 2030, nearly three times the current load.​3 This presents a systemic challenge. The U.S. power grid, built for a different era, is struggling to keep pace. Utilities are reporting record interconnection requests, with some regions seeing demand projections that exceed their total system capacity by fivefold.4 In Virginia and Texas, the epicenters of data center expansion, grid operators are warning of tight supply-demand balances and the risk of blackouts during peak periods.5 The problem is not just the sheer volume of power needed, but the speed at which it must be delivered. Data center operators are racing to secure power for projects that could be online in as little as 18 months, but grid upgrades and new generation can take years, if not decades. The result

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The Future of Hyperscale: Neoverse Joins NVLink Fusion as SC25 Accelerates Rack-Scale AI Architectures

Neoverse’s Expanding Footprint and the Power-Efficiency Imperative With Neoverse deployments now approaching roughly 50% of all compute shipped into top hyperscalers in 2025 (representing more than a billion Arm cores) and with nation-scale AI campuses such as the Stargate project already anchored on Arm compute, the addition of NVLink Fusion becomes a pivotal extension of the Neoverse roadmap. Partners can now connect custom Arm CPUs to their preferred NVIDIA accelerators across a coherent, high-bandwidth, rack-scale fabric. Arm characterized the shift as a generational inflection point in data-center architecture, noting that “power—not FLOPs—is the bottleneck,” and that future design priorities hinge on maximizing “intelligence per watt.” Ian Buck, vice president and general manager of accelerated computing at NVIDIA, underscored the practical impact: “Folks building their own Arm CPU, or using an Arm IP, can actually have access to NVLink Fusion—be able to connect that Arm CPU to an NVIDIA GPU or to the rest of the NVLink ecosystem—and that’s happening at the racks and scale-up infrastructure.” Despite the expanded design flexibility, this is not being positioned as an open interconnect ecosystem. NVIDIA continues to control the NVLink Fusion fabric, and all connections ultimately run through NVIDIA’s architecture. For data-center planners, the SC25 announcement translates into several concrete implications: 1.   NVIDIA “Grace-style” Racks Without Buying Grace With NVLink Fusion now baked into Neoverse, hyperscalers and sovereign operators can design their own Arm-based control-plane or pre-processing CPUs that attach coherently to NVIDIA GPU domains—such as NVL72 racks or HGX B200/B300 systems—without relying on Grace CPUs. A rack-level architecture might now resemble: Custom Neoverse SoC for ingest, orchestration, agent logic, and pre/post-processing NVLink Fusion fabric Blackwell GPU islands and/or NVLink-attached custom accelerators (Marvell, MediaTek, others) This decouples CPU choice from NVIDIA’s GPU roadmap while retaining the full NVLink fabric. In practice, it also opens

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Flex’s Integrated Data Center Bet: How a Manufacturing Giant Plans to Reshape AI-Scale Infrastructure

At this year’s OCP Global Summit, Flex made a declaration that resonated across the industry: the era of slow, bespoke data center construction is over. AI isn’t just stressing the grid or forcing new cooling techniques—it’s overwhelming the entire design-build process. To meet this moment, Flex introduced a globally manufactured, fully integrated data center platform aimed directly at multi-gigawatt AI campuses. The company claims it can cut deployment timelines by as much as 30 percent by shifting integration upstream into the factory and unifying power, cooling, compute, and lifecycle services into pre-engineered modules. This is not a repositioning on the margins. Flex is effectively asserting that the future hyperscale data center will be manufactured like a complex industrial system, not built like a construction project. On the latest episode of The Data Center Frontier Show, we spoke with Rob Campbell, President of Flex Communications, Enterprise & Cloud, and Chris Butler, President of Flex Power, about why Flex believes this new approach is not only viable but necessary in the age of AI. The discussion revealed a company leaning heavily on its global manufacturing footprint, its cross-industry experience, and its expanding cooling and power technology stack to redefine what deployment speed and integration can look like at scale. AI Has Broken the Old Data Center Model From the outset, Campbell and Butler made clear that Flex’s strategy is a response to a structural shift. AI workloads no longer allow power, cooling, and compute to evolve independently. Densities have jumped so quickly—and thermals have risen so sharply—that the white space, gray space, and power yard are now interdependent engineering challenges. Higher chip TDPs, liquid-cooled racks approaching one to two megawatts, and the need to assemble entire campuses in record time have revealed deep fragility in traditional workflows. As Butler put it, AI

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Data Center Jobs: Engineering, Construction, Commissioning, Sales, Field Service and Facility Tech Jobs Available in Major Data Center Hotspots

Each month Data Center Frontier, in partnership with Pkaza, posts some of the hottest data center career opportunities in the market. Here’s a look at some of the latest data center jobs posted on the Data Center Frontier jobs board, powered by Pkaza Critical Facilities Recruiting. Looking for Data Center Candidates? Check out Pkaza’s Active Candidate / Featured Candidate Hotlist Data Center Facility Technician (All Shifts Available) Impact, TX This position is also available in: Ashburn, VA; Abilene, TX; Needham, MA and New York, NY. Navy Nuke / Military Vets leaving service accepted!  This opportunity is working with a leading mission-critical data center provider. This firm provides data center solutions custom-fit to the requirements of their client’s mission-critical operational facilities. They provide reliability of mission-critical facilities for many of the world’s largest organizations facilities supporting enterprise clients, colo providers and hyperscale companies. This opportunity provides a career-growth minded role with exciting projects with leading-edge technology and innovation as well as competitive salaries and benefits. Electrical Commissioning Engineer Montvale, NJ This traveling position is also available in: New York, NY; White Plains, NY;  Richmond, VA; Ashburn, VA; Charlotte, NC; Atlanta, GA; Hampton, GA; Fayetteville, GA; New Albany, OH; Cedar Rapids, IA; Phoenix, AZ; Salt Lake City, UT; Dallas, TX or Chicago, IL. *** ALSO looking for a LEAD EE and ME CxA Agents and CxA PMs. *** Our client is an engineering design and commissioning company that has a national footprint and specializes in MEP critical facilities design. They provide design, commissioning, consulting and management expertise in the critical facilities space. They have a mindset to provide reliability, energy efficiency, sustainable design and LEED expertise when providing these consulting services for enterprise, colocation and hyperscale companies. This career-growth minded opportunity offers exciting projects with leading-edge technology and innovation as well as competitive salaries and

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Microsoft will invest $80B in AI data centers in fiscal 2025

And Microsoft isn’t the only one that is ramping up its investments into AI-enabled data centers. Rival cloud service providers are all investing in either upgrading or opening new data centers to capture a larger chunk of business from developers and users of large language models (LLMs).  In a report published in October 2024, Bloomberg Intelligence estimated that demand for generative AI would push Microsoft, AWS, Google, Oracle, Meta, and Apple would between them devote $200 billion to capex in 2025, up from $110 billion in 2023. Microsoft is one of the biggest spenders, followed closely by Google and AWS, Bloomberg Intelligence said. Its estimate of Microsoft’s capital spending on AI, at $62.4 billion for calendar 2025, is lower than Smith’s claim that the company will invest $80 billion in the fiscal year to June 30, 2025. Both figures, though, are way higher than Microsoft’s 2020 capital expenditure of “just” $17.6 billion. The majority of the increased spending is tied to cloud services and the expansion of AI infrastructure needed to provide compute capacity for OpenAI workloads. Separately, last October Amazon CEO Andy Jassy said his company planned total capex spend of $75 billion in 2024 and even more in 2025, with much of it going to AWS, its cloud computing division.

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John Deere unveils more autonomous farm machines to address skill labor shortage

Join our daily and weekly newsletters for the latest updates and exclusive content on industry-leading AI coverage. Learn More Self-driving tractors might be the path to self-driving cars. John Deere has revealed a new line of autonomous machines and tech across agriculture, construction and commercial landscaping. The Moline, Illinois-based John Deere has been in business for 187 years, yet it’s been a regular as a non-tech company showing off technology at the big tech trade show in Las Vegas and is back at CES 2025 with more autonomous tractors and other vehicles. This is not something we usually cover, but John Deere has a lot of data that is interesting in the big picture of tech. The message from the company is that there aren’t enough skilled farm laborers to do the work that its customers need. It’s been a challenge for most of the last two decades, said Jahmy Hindman, CTO at John Deere, in a briefing. Much of the tech will come this fall and after that. He noted that the average farmer in the U.S. is over 58 and works 12 to 18 hours a day to grow food for us. And he said the American Farm Bureau Federation estimates there are roughly 2.4 million farm jobs that need to be filled annually; and the agricultural work force continues to shrink. (This is my hint to the anti-immigration crowd). John Deere’s autonomous 9RX Tractor. Farmers can oversee it using an app. While each of these industries experiences their own set of challenges, a commonality across all is skilled labor availability. In construction, about 80% percent of contractors struggle to find skilled labor. And in commercial landscaping, 86% of landscaping business owners can’t find labor to fill open positions, he said. “They have to figure out how to do

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2025 playbook for enterprise AI success, from agents to evals

Join our daily and weekly newsletters for the latest updates and exclusive content on industry-leading AI coverage. Learn More 2025 is poised to be a pivotal year for enterprise AI. The past year has seen rapid innovation, and this year will see the same. This has made it more critical than ever to revisit your AI strategy to stay competitive and create value for your customers. From scaling AI agents to optimizing costs, here are the five critical areas enterprises should prioritize for their AI strategy this year. 1. Agents: the next generation of automation AI agents are no longer theoretical. In 2025, they’re indispensable tools for enterprises looking to streamline operations and enhance customer interactions. Unlike traditional software, agents powered by large language models (LLMs) can make nuanced decisions, navigate complex multi-step tasks, and integrate seamlessly with tools and APIs. At the start of 2024, agents were not ready for prime time, making frustrating mistakes like hallucinating URLs. They started getting better as frontier large language models themselves improved. “Let me put it this way,” said Sam Witteveen, cofounder of Red Dragon, a company that develops agents for companies, and that recently reviewed the 48 agents it built last year. “Interestingly, the ones that we built at the start of the year, a lot of those worked way better at the end of the year just because the models got better.” Witteveen shared this in the video podcast we filmed to discuss these five big trends in detail. Models are getting better and hallucinating less, and they’re also being trained to do agentic tasks. Another feature that the model providers are researching is a way to use the LLM as a judge, and as models get cheaper (something we’ll cover below), companies can use three or more models to

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OpenAI’s red teaming innovations define new essentials for security leaders in the AI era

Join our daily and weekly newsletters for the latest updates and exclusive content on industry-leading AI coverage. Learn More OpenAI has taken a more aggressive approach to red teaming than its AI competitors, demonstrating its security teams’ advanced capabilities in two areas: multi-step reinforcement and external red teaming. OpenAI recently released two papers that set a new competitive standard for improving the quality, reliability and safety of AI models in these two techniques and more. The first paper, “OpenAI’s Approach to External Red Teaming for AI Models and Systems,” reports that specialized teams outside the company have proven effective in uncovering vulnerabilities that might otherwise have made it into a released model because in-house testing techniques may have missed them. In the second paper, “Diverse and Effective Red Teaming with Auto-Generated Rewards and Multi-Step Reinforcement Learning,” OpenAI introduces an automated framework that relies on iterative reinforcement learning to generate a broad spectrum of novel, wide-ranging attacks. Going all-in on red teaming pays practical, competitive dividends It’s encouraging to see competitive intensity in red teaming growing among AI companies. When Anthropic released its AI red team guidelines in June of last year, it joined AI providers including Google, Microsoft, Nvidia, OpenAI, and even the U.S.’s National Institute of Standards and Technology (NIST), which all had released red teaming frameworks. Investing heavily in red teaming yields tangible benefits for security leaders in any organization. OpenAI’s paper on external red teaming provides a detailed analysis of how the company strives to create specialized external teams that include cybersecurity and subject matter experts. The goal is to see if knowledgeable external teams can defeat models’ security perimeters and find gaps in their security, biases and controls that prompt-based testing couldn’t find. What makes OpenAI’s recent papers noteworthy is how well they define using human-in-the-middle

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