Electric vehicle (EV) charging infrastructure design is becoming more technically demanding as higher-voltage vehicle platforms, grid constraints, and uptime expectations converge. Decisions around power stages, modularity, and system integration now carry long-term implications for performance and scalability.
Shaheer Ghaznavi, Engineer and Product Manager, BTC POWER.
Shaheer Ghaznavi, engineer and product manager at BTC POWER, has been closely involved in charger design and deployment strategy. Drawing on his experience, he shares his perspective on the technical considerations now shaping EV charging projects.
BTC POWER recently conducted a State of Charging survey to better understand how operators view reliability, performance, and future infrastructure needs. Ghaznavi also touches on findings that signal implications for those designing and deploying EV charging systems.
Here’s what he has to say…
Where should EV infrastructure engineers focus in 2026?
This year, there will be more opportunities to optimize functionality and cost. As the industry evolves, charger suppliers are adding more chargers designed for specific charging applications. For example, 30-minute charging for retail, four-hour charging for theme parks and employee lots, and overnight charging for fleets. A broader range of charger options allows engineers to better match system design to the specific charging application and avoid paying for unnecessary functionality.
As charger segmentation increases, engineers will need to pay closer attention to grid interaction, power quality, and site-level load management. Different duty cycles and power profiles place different stresses on distribution equipment, transformers, and switchgear, making system-level coordination more important than simply selecting higher kW units.
Ideally, engineers should evaluate how chargers respond to peak demand events, harmonics, and load balancing requirements, particularly in constrained grid environments.
Infrastructure planning for EV fleet applications requires coordination of power delivery, modular capacity, and uptime state.
In parallel, the shift toward higher-voltage EV architectures is influencing charger design. With many platforms moving from approximately 400-V packs to 800-V systems and beyond, charging power stages must support higher maximum output voltages and tighter control across a broader operating range.
This affects semiconductor selection, contactors, busbar design, insulation coordination, and high-voltage sensing.
Before selecting a charger, engineers should confirm that the system has sufficient voltage headroom and modular scalability to accommodate future vehicle platforms without requiring full infrastructure replacement.
Is grid capacity becoming a larger concern for EV deployment?
EVs are not the threat to the grid as they were once thought to be. Several studies show that the increased load on the grid is manageable overall, and that EVs may actually help the grid by being a bidirectional energy resource.
Additionally, more charger suppliers are introducing chargers with Energy Star ratings. However, data centers are having a huge impact on the grid, and this may affect the availability of reliable power for a project. Engineers should check the reliability of the power supply with the utility serving that site.
How can infrastructure reliability and uptime be improved?
A recent survey of charger operators shows dissatisfaction with charger reliability and performance. Engineers can mitigate these concerns by selecting chargers with high reliability (98%) and carefully vetting charger software.
More software providers are adopting credit card readers instead of RFID cards and brand-specific apps, which have been a source of irritation among users. The most common question, especially for EV car renters, is, “How do I pay?” The industry needs to get past this.
The survey also shows that operators want more clarity in the information they receive from the data monitoring software. The data they get is like a check engine light: something is wrong, but they can’t see what it is.
The charger supplier should be able to report compatibility test results for the specific software that engineers select for their charging system. The results may vary depending on the model of the vehicle, so engineers need to validate the supplier has a robust testing program.
Beyond software, find a local company that can provide maintenance on a rush basis. Often the charger supplier can recommend a partner who services that geographic area.
What barriers complicate EV charger implementation?
A major challenge for engineers lies in the complexity of charger installations. This includes negotiating with multiple entities, connecting to the grid, communicating to the cloud, integrating third-party software, and even getting grants and filing permits. Some charger suppliers have dedicated teams that assist with all phases of the process.
How can engineers best future-proof EV infrastructure?
The survey shows that the demand for EV chargers is likely to grow and, perhaps surprisingly, that operators are confident in the availability of grants. So, engineering projects need to allow for expansion. One strategy is to start small and add more kilowatts of charging capacity as needed. This can be accomplished by selecting chargers with modular power units that enable engineers to add power without adding new chargers.
The charging cable is another consideration. Development is underway across the industry to support higher-current cables, including 800-A designs that may be required as charging speeds increase beyond the limits of today’s 600-A standard.
Charging hardware design is increasingly influenced by higher-voltage EV platforms and tighter power-stage requirements.
This presents technical challenges related to thermal management, liquid cooling integration, weight, flexibility, and long-term durability under repeated use.
How are higher-voltage EV architectures influencing charging infrastructure design?
The system architecture for fleet charging will be different from the system architecture for a retail location, etc. The power cabinet, charging ports, cable length, mix of charger types, and distances between chargers are all variables to consider. System configuration should be validated against vehicle voltage ranges, duty cycles, and expansion requirements before equipment selection.
Engineers should understand the different types of chargers and how they fit the application. A major package delivery company bought the wrong chargers at a location and a year later had to replace them. Technical due diligence, which includes close consultation with engineers is an ideal strategy for avoiding engineering missteps.
Filed Under: Charging, Featured Contributions, Q&As