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The Next Semiconductor Revolution: How DARPA’s Ultra-Wide Bandgap Program Is Redefining Power Electronics

In the world of microelectronics, efficiency is everything. From data centers and electric grids to radar systems and electric vehicles, the quest for smaller, faster, and more power-efficient devices has driven decades of innovation. Yet silicon—the workhorse of the semiconductor industry—is reaching its physical and performance limits. To break through these barriers, the Defense Advanced Research Projects Agency (DARPA) has launched its Ultra-Wide Bandgap Semiconductor (UWBGS) program, an ambitious initiative designed to unleash a new class of devices that can operate at unprecedented voltages, frequencies, and temperatures. The result could reshape both military and civilian technologies on a global scale.

What Are Ultra-Wide Bandgap Semiconductors?

All semiconductors are defined by their bandgap—the energy needed to move electrons into a conducting state. Conventional silicon, with a bandgap of 1.1 electron volts (eV), has been pushed to its limit. Wide bandgap materials such as silicon carbide (3.3 eV) and gallium nitride (3.4 eV) have already revolutionized power electronics by enabling more efficient switching, higher frequencies, and smaller power devices. Ultra-wide bandgap semiconductors take this even further, with bandgaps above 4 eV. Materials such as aluminum nitride (~6.2 eV), boron nitride (~6.4 eV), diamond (5.5 eV), and gallium oxide (4.5–5.3 eV) exhibit extraordinary resilience, withstanding electric fields that would break down silicon and maintaining performance at temperatures exceeding 500°C. These properties make them ideal candidates for the next leap in high-performance electronics.

UWBGS vs. Si, SiC, and GaN

For decades, silicon (Si) has been the workhorse of power electronics, but its limitations in thermal tolerance, breakdown voltage, and switching efficiency have made it less suitable for the extreme demands of modern defense platforms. Silicon carbide (SiC) and gallium nitride (GaN) emerged as wide-bandgap (WBG) alternatives, delivering superior power efficiency, higher operating temperatures, and reduced system size and weight. These properties have made SiC the material of choice in electric vehicles and grid applications, while GaN has proven invaluable for high-frequency, high-efficiency systems such as radar and communications.

However, the arrival of ultra-wide bandgap semiconductors (UWBGS) marks a step-change rather than an incremental improvement. Materials such as gallium oxide (Ga₂O₃), aluminum nitride (AlN), and diamond possess bandgaps two to three times larger than SiC or GaN, enabling unprecedented voltage handling, thermal stability, and radiation hardness. This translates into more compact, reliable, and efficient systems for applications ranging from directed-energy weapons and high-power radar to space electronics exposed to intense radiation. In effect, UWBGS extend the boundaries of what is possible, where Si, SiC, and GaN begin to hit physical limits.

By combining the safety and resilience of LFP batteries with the performance leap of UWBGS, the defense sector is moving toward an electrified and resilient future where platforms can operate longer, withstand harsher environments, and deliver decisive advantages on the battlefield.

Why DARPA Is Betting on UWBGS

Defense systems demand electronics that are lighter, more resilient, and more powerful than what is commercially available. UWBGS materials promise dramatic improvements across multiple dimensions. Devices built with these semiconductors could achieve far higher power densities, shrinking converters, inverters, and amplifiers into lighter, more compact modules—critical for drones, satellites, and portable defense platforms. Their high-temperature tolerance opens new possibilities for embedding electronics directly inside jet engines, hypersonic vehicles, or space systems, where cooling solutions are impractical. Equally transformative is their ability to operate at higher frequencies, enabling smaller and more capable radar and communication systems. Another advantage is their inherent radiation hardness, which ensures reliability in nuclear environments and the harsh conditions of space.

Inside DARPA’s Program: Breaking Scientific Barriers

The UWBGS program is focused not just on proof-of-concept devices but on addressing the materials science and fabrication roadblocks that have historically held back these exotic semiconductors. Producing large, defect-free wafers of aluminum nitride or boron nitride is extraordinarily challenging, so DARPA is investing in novel crystal growth and synthesis techniques to reduce imperfections and improve scalability. Another hurdle lies in doping—introducing controlled impurities to tailor conductivity—which is far more complex in UWBGS materials than in silicon. The program is supporting the development of new doping methodologies and low-resistance contacts to unlock the full potential of these materials. Finally, DARPA aims to translate these advances into working devices—transistors, diodes, and RF components—that can be integrated into real-world defense systems and, eventually, commercial applications.

DARPA Awards $5.3M to RTX Raytheon to Advance Ultra-Wide Bandgap Semiconductors

In a significant move to advance next-generation semiconductor technology, the U.S. Defense Advanced Research Projects Agency (DARPA) has awarded a $5.3 million contract to RTX’s Raytheon segment for the Ultra-Wide Bandgap Semiconductors (UWBGS) project. Announced on September 13, 2024, this three-year initiative aims to overcome critical material science challenges that have limited the practical application of ultra-wide bandgap materials such as aluminum nitride and boron nitride. These semiconductors, with bandgaps exceeding 4.0 eV, promise to revolutionize power electronics by enabling devices that operate at higher voltages, frequencies, and temperatures than currently possible with silicon or even conventional wide bandgap materials like silicon carbide and gallium nitride.

Raytheon’s research will concentrate on three core technical areas essential to unlocking the potential of UWBGS. First, the team will work on developing large-area, high-quality ultrawide-bandgap substrates, which are fundamental to manufacturing reliable and scalable devices. Second, they will investigate advanced doping techniques to create effective n-type and p-type regions—a major hurdle for materials like aluminum nitride—enabling the formation of high-performance homo- and heterojunctions. Finally, the program will focus on achieving ultralow-resistance electrical contacts, which are critical for minimizing power loss and thermal issues in high-power devices.

The success of this effort could have profound implications for both defense and commercial sectors. By improving material quality, junction design, and electrical contacts, Raytheon aims to pave the way for smaller, more efficient, and radically more robust electronic systems. These advancements could lead to transformative applications in areas such as directed-energy weapons, next-generation radar, compact power converters for electric platforms, and electronics capable of operating in extreme environments, from hypersonic vehicles to space missions. This award underscores DARPA’s continued commitment to maintaining U.S. leadership in foundational technologies that will shape the future of high-performance electronics.

DARPA awards HexaTech AlN substrate development contract

HexaTech Inc. of Morrisville, NC, a subsidiary of Stanley Electric Co. Ltd. of Tokyo, Japan, has secured a multi-year contract with the US Defense Advanced Research Projects Agency (DARPA) under its Ultra-Wide Bandgap Semiconductors (UWBGS) program. HexaTech’s efforts will center on the development of 100mm-diameter, low-defect-density aluminum nitride (AlN) substrates—materials expected to play a pivotal role in high-voltage, high-frequency electronic devices, where performance, efficiency, and reliability are paramount.

Valued at up to $10.2 million over three years, the contract accelerates HexaTech’s prior 100mm substrate development program, scaling its crystal growth and finishing processes to production-ready levels. According to the company, the expansion to 100mm substrates with superior bulk quality is vital to ensure compatibility with modern fabrication lines and to achieve significant performance and reliability gains in next-generation devices. The program aims to transition these substrates into volume production, paving the way for widespread adoption by both commercial and defense foundries and ultimately driving advancements in critical applications across power electronics, RF systems, and beyond.

Potential Applications Across Sectors

If successful, UWBGS technology could redefine the architecture of entire systems. Defense applications would see immediate gains: radars capable of higher resolution and longer range, hypersonic vehicles equipped with electronics that endure extreme heat, and directed-energy weapons that benefit from compact, ultra-efficient power delivery. Space systems could leverage radiation-tolerant electronics to survive solar storms and cosmic radiation, while energy grids could integrate ultra-efficient converters and transformers to stabilize renewable energy flows. Even electric transportation stands to benefit, with lighter, more powerful motor drives and charging systems that could extend the performance envelope of next-generation electric aircraft and vehicles.

The transformative potential lies in the fact that capabilities currently requiring large cabinets of power electronics and complex cooling systems could one day fit in devices no larger than a handheld module. For both military and civilian domains, this would be nothing short of revolutionary.

Challenges and the Path Forward

Despite the promise, UWBGS adoption is far from guaranteed. Producing these materials at wafer scale remains costly and technically complex, with defect densities that limit yield. While they tolerate extreme heat, dissipating the waste heat generated in high-power applications still requires innovative thermal management solutions. Packaging and circuit design must also evolve to handle the unique electrical properties of UWBGS devices. DARPA’s program is designed to confront these issues head-on by uniting universities, national labs, and private industry in a coordinated push to overcome barriers that no single institution could tackle alone.

Conclusion: Powering the Future
DARPA’s Ultra-Wide Bandgap Semiconductor program represents more than just incremental progress—it is a foundational bet on the future of power electronics. While silicon and even today’s wide bandgap materials will continue to dominate mainstream markets, UWBGS devices promise breakthroughs in the most demanding defense, space, and energy applications. Over time, as fabrication improves and costs fall, these technologies will migrate into commercial and industrial systems, reshaping everything from renewable energy integration to electric aviation.

The age of ultra-efficient, ultra-resilient power is on the horizon. And it will be built on the shoulders of ultra-wide bandgap semiconductors.

 

About Rajesh Uppal

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