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Hey everyone,
There's been a lot of questions regarding how our plugs work, so I decided to create this thread to hopefully serve to answer any questions or concerns you might have. It's pretty long, so if you just want a quick summary - I recommend watching the video!
Section I - Introduction
I would like to begin by linking our 'How Pulstar Plugs Work' video. It features actual footage of Pulstar’s plasma-forming pulse and improved fuel burn captured by AVL, a certified testing laboratory frequently used by most major automotive manufacturers. We developed this video in order to clearly explain and highlight complex subjects such as plasma physics, energy compression, and nano-plasma combustion chemistry to the general public.
Pulstar Spark Plugs use innovative plasma-assisted combustion technology to increase horsepower, torque and improve fuel efficiency. Plasma saturated fuel ignites immediately and burns rapidly to improve engine performance.
Plasma-assisted combustion is already used to improve engine performance for racing, but requires complex control systems and costs nearly $2,000 per cylinder. Pulstar Spark Plugs, manufactured by Enerpulse Technologies, brings plasma-assisted combustion to consumers with a simple spark plug upgrade for less than $18 a cylinder. Pulstar uses a patented internal capacitor, developed with the help of a US Department of Energy laboratory, to create a high-intensity electrical pulse that ionizes the air-fuel mixture and saturates it with combustion-enhancing plasma. With its plasma-assisted combustion, Pulstar ignites fuel instantly and burns it rapidly; delivering excellent engine output and wicked throttle response.
Section II - Pulsed Power
Pulstar uses pulsed power technology to create a powerful 5MW pulse of energy upon spark formation. To form a spark, a vehicles ignition coil will slowly (relative to the process) inductively increase the voltage delivered to the spark plug until enough voltage is being delivered to allow electricity to bridge the air-fuel mixture between the center electrode and ground strap of the spark plug. This is known as achieving breakdown voltage. Pulstar Spark Plugs use a patented internal capacitor to store this energy prior to achieving breakdown voltage. When a spark is formed the energy stored in the capacitor is released in a quick and powerful pulse. This pulse is equal to 5,000,000 watts and takes approximately three nanoseconds to complete. The intense converts a portion of the gaseous air-fuel mixture into a highly excited plasma that conditions the fuel mixture to ignite immediately and burn efficiently.
Captured by AVL using a process known as Schlieren high-speed photography, this video shows Pulstar’s 5MW pulse followed by the plasma affected fuel mixture burning at an increased rate compared to a conventional spark plug.
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Energy delivered by the ignition coil prior to the spark is stored in Pulstar’s capacitor and rapidly released when breakdown voltage is achieved.
Section III - Patented Capacitor
Pulstar uses a patented internal capacitor to store and compress energy prior to the spark. Pulstar’s insulator is made of engineered high-purity ceramic, forming a dense barrier between the metal shell (negative plate) and the copper silica gas seal (positive plate.) The insulator acts as a dielectric media, allowing the shell to attract energy but preventing it from crossing. This forces the energy to store on the positive plate until it can cross the spark gap, forming an intense pulse of energy.
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A typical capacitor has three parts: a positive plate, a negative plate, and a dielectric media. The positive plate attracts the energy while the negative plate provides it access to ground. The dielectric media allows the negative plate to attract energy but prevents it from crossing between the two plates, forcing the energy to collect and be “stored” on the positive plate. When the energy is released, a quick and powerful pulse of energy is created; delivering a large amount of instantaneous power over a short period of time.
Dielectric Media (Insulator):
Repurposed by using high-purity, engineered, ceramic. Prevents energy from traveling between the two plates yet allows the shell to act as negative plate.
Negative Plate (Shell):
Normal metal shell. Attracts energy to ground.
Positve Plate (Gas Seal):
Copper silica gas seal. Stores energy unable to access ground.
![]()
Parallel Capacitor
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The capacitor is in parallel with the high voltage circuit, meaning the energy delivered by the ignition coil sees the capacitor and the spark gap simultaneously. While the voltage is ionizing the gap, energy is flowing into the capacitor (charging the capacitor). The resistance across the gap is infinite (open circuit) while the resistance in the capacitor is less than infinite. A resistance reversal takes place when ionization occurs and the spark is formed, the resistance in the gap becomes less than the resistance in the capacitor. The gap acts as a switch, automatically triggering the capacitor. At which point whatever energy is stored in the capacitor (3-10mJ) discharges into the combustion chamber creating the plasma-forming pulse.
Section IV - Plasma-assisted Combustion
Pulstar’s intense pulse breaks apart the gaseous atoms to form highly-excited plasma. Pulstar’s 5MW pulse subjects gaseous atoms to a large amount of energy, breaking them apart to form plasma: a collection of positively and negatively charged highly reactive particles. Plasma created by this high-intensity pulse results in three major benefits in fuel combustion: instant ignition and a quicker and more complete burn.
![]()
Liquid, solid and gas are the three well known states of matter; by subjecting gas to a large amount of electrical energy the fourth state, plasma, is formed.
For instance, this diagram shows gas atoms with a positive core and orbiting negative electrons. To form plasma, these gas atoms are subjected to a large amount of energy and broken apart to form a collection of positively and negatively charged highly reactive particles. Plasma consists of positively charged ions with most or all of their detached electrons moving freely about in a very active manner; these electrons react with other atoms.
![]()
Pulstar stores energy accumulated over a relatively long period of time in its internal capacitor and releases it entirely in less than three nanoseconds. This massive dump of energy happens so quickly that the pulse it forms is equal to 5 megawatts. This 5 MW pulse interacts with the gaseous air-fuel mixture, breaking its molecules apart. This is known as ionization, the process by which an atom or molecule acquires a negative or positive charge by gaining or losing electrons to form ions. By ionizing the gaseous air-fuel mixture, Pulstar breaks down natural elements like H2 and O2 into their atomic state of H and O where they are most volatile. Thus, the portion of the air-fuel mixture affected by the pulse has been turned into plasma.
Plasma created by the high-intensity pulse of energy results in three major benefits in fuel combustion: instant ignition and a quicker and more complete burn.
Instant Ignition
Temperature Increase.The high-intensity pulse creates a flash of heat that helps the fuel charge reach the required light-off temperature to ignite the air-fuel mixture. The flash point for gasoline is about 600oF and 1,100oF for natural gas. The heat provided by the plasma, gives the air-fuel mixture a head start to achieving the temperature required to ignite.
Volatile Air-fuel Mixture. The high-intensity pulse ionizes the gaseous air-fuel mixture, breaking down air-fuel components like H2 and O2 into their atomic state of H and O where they are most volatile. These highly excited elements along with radicals react to the ensuing spark by igniting instantly.
Quicker Burn
Fuel Fragments. The high-intensity pulse breaks apart the long hydrocarbon chains found in the nearby air-fuel mixture into shorter chains that react quickly. This area of the air-fuel mixture burns faster.
Complete Burn
Fuel Fragments. The portion of the fuel that contains shortened hydrocarbon chains burns faster, and creates a larger surface area to ignite the rest of the gaseous air-fuel mixture. This allows the air-fuel mixture to burn more completely during the power stroke.
Ionic Wind. The high-intensity pulse knocks off electrons from the air-fuel mixture molecules. These ions are thrown out of orbit and knock off additional ions from neighboring molecules, creating a cascading effect. This process helps expand the formation of plasma beyond the high-intensity pulse’s immediate vicinity. As previously mentioned, this plasma field burns at an accelerated rate.
![]()
There's been a lot of questions regarding how our plugs work, so I decided to create this thread to hopefully serve to answer any questions or concerns you might have. It's pretty long, so if you just want a quick summary - I recommend watching the video!
Section I - Introduction
I would like to begin by linking our 'How Pulstar Plugs Work' video. It features actual footage of Pulstar’s plasma-forming pulse and improved fuel burn captured by AVL, a certified testing laboratory frequently used by most major automotive manufacturers. We developed this video in order to clearly explain and highlight complex subjects such as plasma physics, energy compression, and nano-plasma combustion chemistry to the general public.
You can watch the video here
Pulstar Spark Plugs use innovative plasma-assisted combustion technology to increase horsepower, torque and improve fuel efficiency. Plasma saturated fuel ignites immediately and burns rapidly to improve engine performance.
Plasma-assisted combustion is already used to improve engine performance for racing, but requires complex control systems and costs nearly $2,000 per cylinder. Pulstar Spark Plugs, manufactured by Enerpulse Technologies, brings plasma-assisted combustion to consumers with a simple spark plug upgrade for less than $18 a cylinder. Pulstar uses a patented internal capacitor, developed with the help of a US Department of Energy laboratory, to create a high-intensity electrical pulse that ionizes the air-fuel mixture and saturates it with combustion-enhancing plasma. With its plasma-assisted combustion, Pulstar ignites fuel instantly and burns it rapidly; delivering excellent engine output and wicked throttle response.
Section II - Pulsed Power
Pulstar uses pulsed power technology to create a powerful 5MW pulse of energy upon spark formation. To form a spark, a vehicles ignition coil will slowly (relative to the process) inductively increase the voltage delivered to the spark plug until enough voltage is being delivered to allow electricity to bridge the air-fuel mixture between the center electrode and ground strap of the spark plug. This is known as achieving breakdown voltage. Pulstar Spark Plugs use a patented internal capacitor to store this energy prior to achieving breakdown voltage. When a spark is formed the energy stored in the capacitor is released in a quick and powerful pulse. This pulse is equal to 5,000,000 watts and takes approximately three nanoseconds to complete. The intense converts a portion of the gaseous air-fuel mixture into a highly excited plasma that conditions the fuel mixture to ignite immediately and burn efficiently.
Captured by AVL using a process known as Schlieren high-speed photography, this video shows Pulstar’s 5MW pulse followed by the plasma affected fuel mixture burning at an increased rate compared to a conventional spark plug.
Energy delivered by the ignition coil prior to the spark is stored in Pulstar’s capacitor and rapidly released when breakdown voltage is achieved.
Section III - Patented Capacitor
Pulstar uses a patented internal capacitor to store and compress energy prior to the spark. Pulstar’s insulator is made of engineered high-purity ceramic, forming a dense barrier between the metal shell (negative plate) and the copper silica gas seal (positive plate.) The insulator acts as a dielectric media, allowing the shell to attract energy but preventing it from crossing. This forces the energy to store on the positive plate until it can cross the spark gap, forming an intense pulse of energy.
A typical capacitor has three parts: a positive plate, a negative plate, and a dielectric media. The positive plate attracts the energy while the negative plate provides it access to ground. The dielectric media allows the negative plate to attract energy but prevents it from crossing between the two plates, forcing the energy to collect and be “stored” on the positive plate. When the energy is released, a quick and powerful pulse of energy is created; delivering a large amount of instantaneous power over a short period of time.
Dielectric Media (Insulator):
Repurposed by using high-purity, engineered, ceramic. Prevents energy from traveling between the two plates yet allows the shell to act as negative plate.
Negative Plate (Shell):
Normal metal shell. Attracts energy to ground.
Positve Plate (Gas Seal):
Copper silica gas seal. Stores energy unable to access ground.
Parallel Capacitor
The capacitor is in parallel with the high voltage circuit, meaning the energy delivered by the ignition coil sees the capacitor and the spark gap simultaneously. While the voltage is ionizing the gap, energy is flowing into the capacitor (charging the capacitor). The resistance across the gap is infinite (open circuit) while the resistance in the capacitor is less than infinite. A resistance reversal takes place when ionization occurs and the spark is formed, the resistance in the gap becomes less than the resistance in the capacitor. The gap acts as a switch, automatically triggering the capacitor. At which point whatever energy is stored in the capacitor (3-10mJ) discharges into the combustion chamber creating the plasma-forming pulse.
Section IV - Plasma-assisted Combustion
Pulstar’s intense pulse breaks apart the gaseous atoms to form highly-excited plasma. Pulstar’s 5MW pulse subjects gaseous atoms to a large amount of energy, breaking them apart to form plasma: a collection of positively and negatively charged highly reactive particles. Plasma created by this high-intensity pulse results in three major benefits in fuel combustion: instant ignition and a quicker and more complete burn.
Liquid, solid and gas are the three well known states of matter; by subjecting gas to a large amount of electrical energy the fourth state, plasma, is formed.
For instance, this diagram shows gas atoms with a positive core and orbiting negative electrons. To form plasma, these gas atoms are subjected to a large amount of energy and broken apart to form a collection of positively and negatively charged highly reactive particles. Plasma consists of positively charged ions with most or all of their detached electrons moving freely about in a very active manner; these electrons react with other atoms.
Pulstar stores energy accumulated over a relatively long period of time in its internal capacitor and releases it entirely in less than three nanoseconds. This massive dump of energy happens so quickly that the pulse it forms is equal to 5 megawatts. This 5 MW pulse interacts with the gaseous air-fuel mixture, breaking its molecules apart. This is known as ionization, the process by which an atom or molecule acquires a negative or positive charge by gaining or losing electrons to form ions. By ionizing the gaseous air-fuel mixture, Pulstar breaks down natural elements like H2 and O2 into their atomic state of H and O where they are most volatile. Thus, the portion of the air-fuel mixture affected by the pulse has been turned into plasma.
Plasma created by the high-intensity pulse of energy results in three major benefits in fuel combustion: instant ignition and a quicker and more complete burn.
Instant Ignition
Temperature Increase.The high-intensity pulse creates a flash of heat that helps the fuel charge reach the required light-off temperature to ignite the air-fuel mixture. The flash point for gasoline is about 600oF and 1,100oF for natural gas. The heat provided by the plasma, gives the air-fuel mixture a head start to achieving the temperature required to ignite.
Volatile Air-fuel Mixture. The high-intensity pulse ionizes the gaseous air-fuel mixture, breaking down air-fuel components like H2 and O2 into their atomic state of H and O where they are most volatile. These highly excited elements along with radicals react to the ensuing spark by igniting instantly.
Quicker Burn
Fuel Fragments. The high-intensity pulse breaks apart the long hydrocarbon chains found in the nearby air-fuel mixture into shorter chains that react quickly. This area of the air-fuel mixture burns faster.
Complete Burn
Fuel Fragments. The portion of the fuel that contains shortened hydrocarbon chains burns faster, and creates a larger surface area to ignite the rest of the gaseous air-fuel mixture. This allows the air-fuel mixture to burn more completely during the power stroke.
Ionic Wind. The high-intensity pulse knocks off electrons from the air-fuel mixture molecules. These ions are thrown out of orbit and knock off additional ions from neighboring molecules, creating a cascading effect. This process helps expand the formation of plasma beyond the high-intensity pulse’s immediate vicinity. As previously mentioned, this plasma field burns at an accelerated rate.
