Flex is strengthening its position in automotive electrification with a comprehensive portfolio of high-voltage power electronics solutions engineered to support the industry's transition toward software-defined vehicles and 800 V battery architectures. By combining advanced engineering capabilities with vertically integrated manufacturing, the company is enabling automakers to develop highly efficient, compact, and scalable electric powertrain systems for next-generation electric vehicles.
As EV manufacturers increasingly migrate from conventional 400 V platforms to higher-voltage architectures, power electronics have emerged as a critical enabler for faster charging, improved energy efficiency, and increased vehicle range. Flex is addressing these requirements through an integrated approach encompassing the design, industrialization, and production of key high-voltage subsystems, including traction inverters, onboard chargers (OBCs), DC-DC converters, battery disconnect units (BDUs), and complete power electronics assemblies.
The company has developed scalable and modular power electronics architectures capable of supporting both 400 V and 800 V battery systems, allowing OEMs to leverage common platforms across multiple vehicle segments while reducing development complexity and accelerating time-to-market. This modular strategy enables greater design flexibility and facilitates platform reuse across evolving vehicle programs.
Beyond conventional power conversion functions, Flex is also advancing vehicle electrical architectures with backup DC-DC converters that can replace conventional auxiliary low-voltage batteries while operating alongside the primary DC-DC converter. Based on a dual active bridge (DAB) architecture, the solution delivers ultra-fast and bidirectional power conversion while achieving high power density and supporting ASIL D-ready functional safety requirements. By eliminating the need for dedicated LV batteries, the architecture enables significant reductions in system cost, weight, and complexity. These solutions have been validated at the component level across multiple use cases, providing OEMs with a scalable and robust platform for next-generation software-defined vehicles.
Flex's engineering approach integrates electrical, mechanical, thermal, and manufacturing disciplines to optimize overall system performance. Through advanced simulation and modeling techniques, the company is able to address critical challenges associated with high-voltage operation, including thermal dissipation, electromagnetic compatibility (EMC), insulation coordination, and long-term reliability under demanding automotive operating conditions.
A major focus of Flex's development efforts lies in increasing power density while minimizing package size and weight. By employing advanced packaging technologies and high-density integration techniques, the company is enabling more compact power conversion systems that contribute to improved vehicle efficiency and extended driving range. The reduction of parasitic effects and optimization of thermal paths further enhance system robustness and overall energy conversion performance.
In addition to subsystem development, Flex provides end-to-end support across the product lifecycle, spanning concept definition, design engineering, prototyping, validation, industrialization, and high-volume manufacturing. This vertically integrated model enables customers to streamline supply chains and accelerate the commercialization of electrified vehicle platforms.
The company's manufacturing infrastructure incorporates advanced automation technologies, digital manufacturing tools, and sophisticated inspection methodologies to ensure consistent quality and traceability. Leveraging its global manufacturing footprint and automotive-grade processes, Flex supports large-scale production of complex high-voltage assemblies while meeting stringent industry requirements for reliability and functional safety.
As software-defined vehicles continue to drive greater system integration, Flex is also focused on enabling consolidated power electronics architectures that reduce component count and enhance packaging efficiency. The company's capabilities in mechanical integration, thermal management, and system-level optimization position it to address the growing demand for highly integrated ePowertrain solutions capable of supporting future electrified mobility platforms.
By combining engineering expertise with advanced manufacturing and supply-chain capabilities, Flex aims to help automotive OEMs accelerate the adoption of high-voltage architectures and deliver electric vehicles with improved efficiency, higher power density, and enhanced system performance.
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About Flex
Flex is a global provider of advanced manufacturing, design, engineering, and supply-chain solutions headquartered in Austin, Texas. Serving industries including automotive, healthcare, industrial, communications, and consumer technologies, the company offers end-to-end support from product conception through volume production. Within the automotive sector, Flex provides technologies for vehicle electrification, power electronics, connectivity, and intelligent mobility systems.
