Star power may be the driving force behind Hollywood’s global popularity, but what really powers box office hits goes largely unnoticed. Most production companies today rely on noisy, environmentally harmful gasoline and diesel generators to operate their movie sets. But as these become more elaborate—with enormous footprints and an expanding array of specialized electronics—energy demands have escalated, as have unwanted levels of dangerous CO₂ emissions.

ReVolt Holdings, Inc. (ReVolt) has developed a better way to power movie sets and studio backlots by providing clean, mobile, always-on electricity. ReVolt systems power everything—from cameras, sound and lighting equipment to special effects rigs and basecamps—quietly, efficiently and with no CO₂ output. Founded in 2020, the startup is quickly gaining traction, partnering with the likes of Amazon MGM Studios, Apple Studios, Sony Pictures, Warner Bros. Discovery and its subsidiary HBO, to power their sets.

Figure 1: ReVolt Holdings, Inc. (ReVolt) has developed a better way to power movie sets and studio backlots by providing clean, mobile, always-on electricity. ReVolt systems power everything—from cameras, sound and lighting equipment to special effects rigs and basecamps—quietly, efficiently and with no CO₂ output.

ReVolt clean power systems silence legacy diesel generators

J.D. Schwalm cut his teeth developing special effects for his first company, Innovation Workshop, before founding ReVolt. As ReVolt’s CEO, Schwalm has emerged as an advocate for replacing diesel generators with cleaner, more efficient power.

A single 10kW diesel generator emits about 75dB of noise—roughly the same as a leaf blower—and produces as much CO₂ in 12 hours as a gas car traveling 225 miles. Because of their sound and exhaust fumes, diesel power sources are typically installed 1,000 feet or more from the set location, which requires thousands of feet of costly, cumbersome cables.

Diesel generators also produce “dirty” power that requires extra filtration when used in sensitive digital lighting and motion control equipment. ReVolt charging systems produce a pure sine wave profile that ensures a clean, stable power source. And they are nearly silent, emitting noise akin to a computer fan.

Figure 2: ReVolt has an expanding fleet of portable power units, all delivering uninterrupted power. Available now, the WeVolt (shown here) is the smallest option for industrial-grade three-phase power.

ReVolt’s patented continuous power delivery is a breakthrough advancement

ReVolt emerged when Schwalm saw a challenge maintaining steady, always-on power from a finite battery source while accommodating the variable power loads of an entire movie set.

“You can make all the power you want with a diesel generator, if you keep fuel in the tank. There wasn’t a battery system in the world that did that,” he said. “That’s when ReVolt came to be—with a battery generator system that is capable of operating while simultaneously being charged.”

ReVolt designed its uninterrupted power technology into an expanding fleet of portable vehicles. The smallest, the WeVolt, generates 17.5kWh capacity and 14kW output—equivalent to a small house generator. The 8,500 pound Mule delivers 210kWh of capacity and 120kW of output power, supplying on-demand energy across 480V, 208V, 240V and 110V connections. In 2024, Schwalm and his team were awarded two patents for their continuous battery power supply design and have another three pending.

Vicor power-dense modules ensure reliability, performance and efficiency

To ensure stable voltage levels, ReVolt adopted Vicor BCM® bus converters, DCM™ DC-DC converters, and most recently, PRM™ regulators.

The BCM4414 converts and isolates 800V into a 48V at 35A bus, which the DCM3414 taps off to regulate 24V loads. The 770W/in³ BCM4414 (4.35 x 1.4 x 0.37in) also serves as a battery emulator, reducing the need for a conventional and bulky 48V battery. The PRM is a non-isolated buck-boost DC-DC regulator capable of converting 48V into various output voltages, with power density exceeding 2kW/in³ and 96% efficiency.

“With one Vicor module, we can do what it would take six or eight components to achieve,” Schwalm said.

The sequel: Powering disaster zones, hospitals and more

Portable, clean energy is in demand today more than ever. As it imprints its power concept on the film industry, ReVolt is preparing to address a variety of new applications, from servicing natural disaster zones to providing power for construction and live events. With the trend toward eMobility and greener, more sustainable power, the relationship with Vicor—grounded in modular power delivery—is gaining momentum and setting the stage for a greener future.

Learn more about ReVolt and how portable, clean energy is in demand today more than ever.

About Vicor

Vicor Corporation designs, develops, manufactures and markets modular power components and complete power systems based upon a portfolio of patented technologies. Headquartered in Andover, Massachusetts, Vicor sells its products to the power systems market, including enterprise and high performance computing, industrial equipment and automation, telecommunications and network infrastructure, vehicles and transportation, aerospace and defense. www.vicorpower.com

Vicor is a registered trademark and BCM®, DCM™, and PRM™ are trademarks of Vicor Corporation.

About ReVolt