The Future of Wire Harnesses in the Electric Vehicle and Electronics Era

Krishna Sundaram
|  Created: January 29, 2025  |  Updated: February 11, 2025
Wire Harnesses in the Electric Vehicle and Electronics

As the automotive and electronics industries transition toward an electrified future, the wire harness—a critical yet often overlooked component of electrical systems—is transforming remarkably. These harnesses are essential for connecting and managing the numerous electrical and electronic components within vehicles and advanced devices. With the rise of electric vehicles (EVs) and increasingly intricate electronics, wire harness design, manufacturing, and functionality are evolving rapidly. Let's explore what lies ahead for these systems in the EV and electronics era.

Increasing Complexity with EVs and Advanced Electronics

Electric vehicles rely significantly more on electrical systems than traditional internal combustion engine (ICE) vehicles. Similarly, the expanding complexity of consumer electronics, industrial automation, and IoT devices demands robust and reliable electrical connectivity. EVs replace conventional engines with electric motors, battery management systems, power electronics, advanced sensors, and sophisticated software. Meanwhile, trends like miniaturization and multifunctionality in electronics further add to the challenge.

As a result, automotive wire harness designs are becoming more sophisticated to enable seamless power distribution, communication, and reliability. Engineers must address challenges such as higher voltages in EVs, faster electronic data transmission speeds, strict safety requirements, reducing weight, saving space, and maximizing durability.

Prioritizing Lightweight and Sustainable Solutions

For both EVs and electronics, reducing weight is critical. In EVs, lighter wire harnesses can improve driving range while enhancing portability and efficiency in electronics. Innovations such as aluminum wiring instead of copper, flat cables, and miniaturized connectors are helping meet these weight reduction goals without sacrificing performance.

Sustainability is also a growing priority. Industries are moving toward greener manufacturing, which includes evaluating automotive wire harness materials for their recyclability and environmental footprint. Future designs may incorporate bio-based materials or recycled plastics to align with ecological goals.

EV car battery pack

High-Voltage Systems and Faster Data Transmission

EVs differ from ICE vehicles in requiring high-voltage wiring systems (typically 400V to 800V or more) to transfer power from the battery to the motor and other components. These systems demand advanced insulation, thermal management, and shielding to ensure safety and performance. New materials and design innovations make these systems more compact and heat-resistant.

In electronics, the focus is on high-speed data transfer and signal quality. Wire harnesses now need to support fast communication standards like USB-C, HDMI 2.1, and Thunderbolt while ensuring reliable power delivery. Reducing electromagnetic interference (EMI) is a key focus in compact, densely packed systems.

The Shift to Modular and Smart Harnesses

Wire harness manufacturers increasingly adopt modular designs to keep up with evolving system architectures. Modular harnesses feature standardized connectors and components, simplifying assembly and maintenance while making production scalable for automakers and electronics manufacturers.

Additionally, the concept of "smart" wire harnesses is gaining traction. These advanced harnesses integrate sensors and diagnostics directly into the wiring, allowing real-time monitoring of parameters like voltage, temperature, and current. Smart harnesses enhance reliability and support predictive maintenance in electronics, particularly in critical applications like medical devices, robotics, and industrial automation.

Automation and Advanced Manufacturing

The growing complexity of wire harnesses has driven significant advancements in manufacturing techniques. Due to the intricate nature of the process, wire harness assembly has traditionally relied heavily on manual labor. However, automation and robotics are now improving efficiency and precision.

Technologies like 3D printing and digital twinning are also emerging to streamline wire harness prototyping and testing, which helps reduce time-to-market and production costs. These advancements are set to become significant competitive advantages for manufacturers in both the EV and electronics sectors.

Cable manufacturing machine

Challenges Ahead

While the future of wire harnesses is filled with potential, several challenges remain. Manufacturers must balance the need for smaller, lighter, and more complex harnesses with cost constraints. Additionally, global supply chain disruptions—such as those seen during the COVID-19 pandemic—highlight the importance of localized production and resilient supply chains.

Another critical challenge is achieving standardization. With diverse EV platforms, varying electronic architectures, and regional regulatory requirements, creating universal standards for automotive wire harness design and manufacturing is challenging. Collaboration between automakers, electronics manufacturers, suppliers, and regulatory bodies will be vital to overcoming this hurdle.

Conclusion

As electric vehicles and advanced electronics continue to shape their respective industries, wire harnesses will be increasingly important in ensuring efficiency, safety, and functionality. The wire harness industry is meeting the demands of electrification and connectivity through advancements in materials, designs, and production techniques.

In this era of rapid technological progress, wire harnesses are no longer just passive components—they are becoming critical enablers of intelligence and connectivity. For engineers, manufacturers, and innovators, the future holds exciting opportunities to redefine the backbone of modern technology.

About Author

About Author

Krishna Sundaram joined Altium as a Senior Product Manager, leading the company's product design area, which includes Multiboard and Harness solutions. With over 11 years of experience in product development within the ECAD industry, Krishna has built his career specialising in the cable and wire harness domain.

He has played a pivotal role in developing innovative software solutions for wire harness design, streamlining workflows, and enhancing engineer productivity. His expertise spans the entire lifecycle of wire harness development—from conceptual design to manufacturing optimisation—ensuring end-to-end efficiency and precision.

Krishna’s in-depth understanding of the complexities wire harness engineers face has driven him to create tools that integrate seamlessly with ECAD ecosystems, bridging the gaps between electrical and mechanical design. His forward-thinking approach has been instrumental in reducing design times and improving collaboration across teams.

A Master's degree in Electrical Power from Newcastle University gives Krishna a solid foundation in electrical systems, which he leverages to pioneer advancements in wire harness technology. Driven by a passion for empowering engineers, Krishna continues to shape the future of harness design through innovative and impactful solutions.

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