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At Munro & Associates, we’ve had the pleasure of tearing down and analyzing some of the world’s most groundbreaking technologies. But every now and then, something truly unique crosses our path. That was certainly the case when we toured Hyliion’s facility and got an exclusive look at their game-changing KARNO generator. What we discovered was more than an engine. It was a whole new philosophy of power generation.
From Trucks to Power: Hyliion’s Shift in Focus
Hyliion founder Thomas Healy started the company back in 2015 with a vision for electrified transportation. But as the EV space evolved, so did Hyliion. The company has since pivoted away from electric trucks and moved into distributed power generation. The goal? Enable facilities—from data centers to marine vessels—to make their own clean, efficient power on-site.
And they’re not just talking the talk. Hyliion’s KARNO generator is a 200-kilowatt fuel-agnostic, linear generator. It’s silent, highly efficient, and built using advanced additive manufacturing. In short, it’s unlike anything we’ve ever seen.
Fail Fast, Learn Faster: Inside the Hall of Innovation
One of the first stops on our tour was Hyliion’s so-called “Hall of Shame.” It’s a space filled with the prototypes, missteps, and test pieces that represent the trials and errors of engineering innovation. But to us, this was no hall of shame. It was a hall of progress. Their “fail fast” philosophy promotes rapid development by encouraging experimentation and embracing mistakes as learning opportunities.
A third-generation 25-kilowatt prototype stood on display, built with easily swappable parts for rapid iteration. The culmination of this experimentation now resides in a sleek, fully integrated 200-kilowatt production model. And it’s impressive.
How the KARNO Generator Works
At its core, the KARNO generator is a linear heat generator powered by fuel-oxidation rather than combustion. The system includes four main sections:
- Linear Motor: Generates electricity as magnets pass through copper coils.
- Cold Side: Compresses and cools helium using a water loop.
- Heater: Warms the helium for expansion.
- Reactor: Converts fuel into heat.
The system is fully sealed, contains no oil or lubricants, and uses gas bearings to reduce maintenance. It’s designed to start in about 30 seconds and reach full power in just four minutes. A “hot standby” mode keeps it ready for action when quick reactivation is needed.
And the best part? It boasts a net efficiency of 50%. That’s about double what you’d expect from a conventional diesel or gas generator.
Additive Manufacturing: Unlocking Design Possibilities
Hyliion’s engineering marvel wouldn’t be possible without additive manufacturing. Essentially metal 3D printing, this process allows the creation of complex geometries that traditional machining could never achieve. Components with microscopic fins, internal chambers, or “a ball within a ball” designs are now feasible and economically viable.
Their facility boasts one of the largest installed bases of metal additive machines in North America—if not the world. Most components are printed with minimal post-processing, further reducing waste and cost. In fact, over 99% of unused powder is recycled for future prints, making the entire process remarkably green.
The Future is Modular—and Fuel Agnostic
One of the most exciting aspects of Hyliion’s KARNO generator is its fuel flexibility. It can run on over 20 different fuels—including natural gas, propane, hydrogen, and even heavier liquids. All without any internal timing or compression ratios to worry about. The system includes a smart fuel-sensing algorithm that detects the fuel type and automatically adjusts flow rates for optimal heat production.
The modularity doesn’t stop there. Need more power? Just stack multiple units together. Want to go smaller? Hyliion’s already thinking about a scaled-down version for household use.
Ultra-Low Emissions Without After-Treatment
Another area where the KARNO system shines is emissions. Because it uses a slow, continuous oxidation process instead of explosive combustion, it significantly reduces CO2 and NOx levels. The low-temperature reaction and exhaust recuperation system allow the unit to meet even California’s strictest emissions regulations. And without the need for a catalytic converter or any after-treatment system.
Real-World Applications: From Data Centers to Naval Ships
The list of potential applications for the KARNO generator is long and diverse. Hyliion is currently focused on five key sectors:
- Data Centers – Decentralized, on-site power reduces reliance on aging grids.
- EV Charging – Clean, efficient power where it’s needed most.
- Waste Gas Recovery – Turn emissions from landfills and dairy farms into usable energy.
- Prime Power for Facilities – Eliminate dependency on the grid with standalone power.
- Marine & Navy – Silent, low-maintenance generators for vessels, ideal for both commercial and military applications.
The U.S. Navy, in particular, is exploring the KARNO system for use on autonomous ships where maintenance access is limited. Its low noise, vibration, and maintenance make it a natural fit.
Hands-On Experience: Quiet, Clean, and Cool
We had the chance to see the full unit running in person, and it was a show-stopper. With four out-of-phase shafts, the system was so smooth that a quarter could be balanced upright on the frame while running. The fan noise was louder than the generator itself.
From a user interface standpoint, the system is plug-and-play. A touchscreen HMI gives customers access to everything from voltage settings to maintenance alerts. The system is LTE-connected, fully remote-monitorable, and can even be paired with batteries or solar fields for hybrid installations.
The Road Ahead: Scaling to Meet Demand
Hyliion’s immediate future is focused on ramping up production of the 200-kilowatt system, with plans for a 2-megawatt version by 2026. And beyond that? Possibly even a 20–25 kilowatt home model.
Thomas Healy summed it up best: “I think of this as the right way to make electricity.” The dream is a world where buildings, homes, and ships can generate their own clean, efficient power on-site—reliably and quietly.
Final Thoughts on the KARNO Generator
What Hyliion has built isn’t just an engine. It’s an ecosystem. It’s the culmination of bold vision, deep engineering expertise, and fearless iteration. Whether it’s powering a data center, an EV charger, or a fishing trawler, Hyliion’s KARNO generator is a glimpse into the future of power.
At Munro & Associates, we’ll be keeping a very close eye on where this technology goes next—and we’ll be rooting for it every step of the way.