Abstract: As the world’s recognized next-generation semiconductor that will replace Si material, Silicon carbide（SiC） has advantages of high voltage rating, fast switching speed, and low switching loss. It is the key factor to realize the power density improvement of automotive motor controllers. In this paper, the design methods of SiC metal-oxidesemiconductor field-effect transistor（MOSFET） module, DC-link capacitor, control and drive circuit, and electromagnetic interference（EMI） filter, as key components in a SiC controller, are discussed. In terms of the SiC module, the layout evaluation system of multi-chip parallel structure MOSFET was studied. Based on this, a SiC MOSFET module including 72 SiC chips was developed. For DC-link capacitor, in order to reduce the volume, its frame was designed simultaneously with the controller housing. Also, its electrical parameters were delicately selected based on mathematical models describing the relationship between the motor system performance and the capacitance as well as the allowable ripple current of the capacitor. In terms of control and drive circuits, the circuit area of the electronic system was reduced by means of non-isolated power supply systems, multi-layer printed circuit boards, etc. An ultra-compact credit-card-sized control board and a compact drive board which can be directly mounted onto the SiC module were developed. For the EMI filter, a synchronization design method of filter topology and components parameters was proposed to solve the problem of repeated trail-and-procedure and to avoid over design. Based on the above research results, a full SiC motor drive controllerwith 85 kW peak power, 20 kHz switching frequency, 98.6% maximum efficiency, and 37.1 kW/L power density was developed.