AI is pushing rack densities and power demands higher than the data center industry has ever seen, leaving operators and engineers questioning how to approach power distribution decisions.

Previously, data center design work was more stable. A topology would be adopted, and that would be the engineer’s framework for some time. Now, the game has changed, and the AI boom means existing power requirements that may have been fine in the past are no longer sufficient.

Having seen significant changes over the past 17 years at Starline, Mark Swift, VP of engineering and product management, shares how equipment manufacturers in particular must keep pace with market changes.

“What we’re seeing from the market, from engineers, and end users, is this acceleration of the design intervals and a push to future-proof how these facilities are going to be used,” he explains during a recent DCD>Talks episode.

AI pressures and technology time-to-market keep intensifying, meaning that IT equipment, power infrastructure, and facility infrastructure are all expected to change. The work of power distribution manufacturers is no longer as clear-cut.

“Data centers are often ahead of where the standards bodies are. We’re seeing customers pushing the envelope, and their leadership is tasking them with finding solutions that will fit and can be deployed at scale, and they don’t want to be beholden to today’s standards if those standards are holding them back,” Swift says. “Where in the past people were very risk-averse, today it seems like there is somewhat of a ‘wild west’ approach.”

Swift first joined Starline in 2010, but has been leading the engineering, R&D, and product management teams for the last eight years. Known as a leader in the data center busway space, Starline has pioneered plug-in units in the market – and only continues to innovate.

“Our customization – configured-to-order plug-in units – is something we’re known for in the industry,” he adds. “Starline has established the ability to work directly with customers to decide how they want power to be delivered to their racks.”

“On the back end, we perform rigorous testing,” he says. “We have automated plug testers that are purpose-designed and built for our application. Every plug-in unit that leaves a Starline facility is run through that automated plug tester.”

Starline’s work comes as lead times are stretched, and some engineers are considering sourcing plug-in units from third parties to keep projects moving. Swift explains the risks associated with this approach, confirming that it’s not permitted to have a third party manufacturer produce plugs for another company’s busway.

“There’s risk to the end user,” he says. “There is no way for a third party entity to ensure compatibility across every system that is globally available.”

As demand continues to grow, Swift advises upsizing busways in anticipation that more power will be needed. He argues that the busway infrastructure is the most expensive portion of the development and a necessary investment, given how quickly the industry is shifting.

“The pace of change right now is incredible. I’ve never seen anything like it in my career,” he says. “It’s so accelerated that, within a given 12- to 18-month cycle, we’ve seen long-term customers change ampacities three times.

“From a high level, I would try to future-proof your facility as much as you can – especially given how quickly things are changing. The best way to do that is to deploy a higher level of busway ampacity than you need today.”

Click here to listen to the full DCD>Talks interview with Mark Swift.