Hyliion uses metal additive manufacturing for new power generation tech

Hyliion, a company initially focused on converting semi-trucks from diesel to electric, has shifted its focus to power generation. This strategic pivot was influenced by challenges in the electric vehicle market, including bankruptcies of peers, difficulties in capital raising, and slower fleet adoption rates.

In 2022, Hyliion acquired GE Aerospace's KARNO power generation technology for $37 million. The company has since concentrated its efforts on this technology, moving it from product development to commercialization. Hyliion has iterated on the KARNO design multiple times, leading to the launch of the KARNO 200-kilowatt power module.

The KARNO 200kW module is a linear heat generator designed to produce electricity on-site using heat as a fuel source. This technology is targeted at applications such as data centers needing supplemental power, shopping malls seeking cheaper electricity than grid options, and military applications like powering unmanned ships.

Hyliion is also developing larger, megawatt-scale power generation solutions based on the KARNO technology, which is described as inherently scalable. The complexity of the KARNO product's heat exchangers makes additive manufacturing the preferred production method, a workflow inherited from GE Aerospace. Challenges related to the size of additive manufacturing build volumes are being addressed by using multiple smaller units for higher power demands, with ongoing development for larger modules.

The KARNO power generation products function similarly to Stirling engines, utilizing a rapid heating and cooling process to drive a piston and generate electricity. While this engine class is decades old, additive manufacturing has enabled the complex designs required for modern applications, allowing Hyliion to bring these solutions to market.