The NEFTON research consortium has achieved a key milestone in the development of next-generation megawatt charging technology after successfully demonstrating a stable charging current of 3,000 amperes during laboratory testing.
The project, led by MAN Truck & Bus together with research and industry partners, said the breakthrough could support charging capacities of up to 3 megawatts for future battery-electric heavy-duty trucks.
Advancing Megawatt Charging
Launched in 2021, the NEFTON project focuses on developing high-power charging technologies for battery-electric commercial vehicles using the Megawatt Charging System (MCS).
Initial work centered on existing megawatt charging capabilities before expanding toward charging power of up to 3 MW.
According to MAN, the latest tests successfully maintained a stable 3,000-amp charging current between the vehicle and test-bench infrastructure.
The testing campaign was conducted at the Technical University of Munich and the Fraunhofer Institute for Solar Energy Systems (Fraunhofer ISE) in Freiburg.
Preparing for Faster Truck Charging
The consortium said the tests generated valuable data on thermal management, cooling systems, switching components and overall safety architecture needed for future ultra-high-power charging systems.
If commercialized, charging at this level could allow electric trucks to recover approximately 400 kilometers of driving range in as little as 10 to 15 minutes.
New Components Required
Project partners noted that conventional automotive charging components are not capable of handling such high electrical currents.
While current megawatt charging systems typically operate at around 800 volts and 1,250 amperes, achieving 3 MW requires currents of approximately 3,000 amperes at the same voltage.
To support those levels, the project redesigned several critical components, including:
- Low-resistance high-current pathways
- Liquid-cooled charging cables and connectors
- High-capacity switching devices and contactors
- Vehicle-side integration optimized for safety, weight and installation
The consortium said minimizing electrical resistance and effectively managing heat were among the project’s primary engineering challenges.
Supporting Commercial Freight Operations
The researchers said ultra-fast charging could be particularly valuable for freight operations where trucks cannot fully recharge during mandatory driver rest periods or overnight.
High-power charging may also benefit operations involving two-driver crews or logistics schedules requiring minimal downtime.
The project team added that future high-speed charging capabilities could eventually allow manufacturers to reduce battery sizes by relying on multiple rapid charging sessions throughout the day.
Next Steps
Although the successful 3,000-amp demonstration marks an important technical achievement, the consortium said commercial deployment will require a new generation of battery systems specifically designed to accept significantly higher charging rates.
Future developments will need advances in battery cell chemistry, module architecture and electrical integration, along with further improvements to charging infrastructure.
MAN parent company Traton said it will continue advancing the technology after the NEFTON project concludes, including work on production-ready high-current charging systems, bidirectional charging functions and megawatt charging solutions capable of operating at up to 3,000 amperes.
The NEFTON consortium includes MAN Truck & Bus, AVL, the Technical University of Munich, Fraunhofer ISE, Prettl Electronics Automotive, the Research Centre for Energy Economics and Deggendorf University of Applied Sciences. The project has received funding from Germany’s Federal Ministry for Economic Affairs and Climate Action.