Flexible & Printed Electronics: How They Complement Traditional Wire Harnesses

Krishna Sundaram
|  Created: February 3, 2025
Closeup a flexible printed circuit of keypad membrane on engineer hand in blue glove

Technology is evolving fast, and industries always want to make electrical systems lighter, more efficient, and adaptable. One of the most significant innovations in making waves is flexible and printed electronics—but does this mean traditional wire harnesses are becoming obsolete? Not at all.

From bendable circuits in wearables to printed sensors in smart packaging, these innovations are shaking things up. However, wire harnesses remain irreplaceable when it comes to power transmission, reliability, and durability. The real future isn't about choosing one over the other—it's about finding ways for wire harnesses and flexible electronics to work together for better performance and efficiency.

What Are Flexible & Printed Electronics?

Flexible and printed electronics use conductive inks, thin substrates, and flexible materials to create circuits that can bend, stretch, or fit into unusual spaces. They're great for low-power applications, but traditional wire harnesses do the heavy lifting when serious power and reliability are needed.

Key Technologies in Flexible & Printed Electronics

1. Conductive Ink Printing

  • It uses silver, copper, or carbon-based inks to create conductive pathways.
  • Perfect for low-power applications like RFID and sensors, but not built for the heavy electrical loads that wire harnesses handle.

2. Flexible Substrates

  • Materials like polyimide and PET allow circuits to bend and flex.
  • They are suitable for touch-sensitive interfaces but lack traditional harnesses' shielding and durability.

3. Hybrid Systems

  • A combination of printed electronics for lightweight applications and traditional wire harnesses for power-intensive and mission-critical functions.
  • It is already used in automotive dashboards, medical wearables, and industrial IoT.
Closeup of optical sensor on electronic printed circuit board and flex ribbon cables on dark blue background

Applications & the Continued Role of Wire Harnesses

1. Automotive & Electric Vehicles (EVs)

Modern vehicles use printed electronics for lightweight controls, but wire harnesses are still crucial for power distribution, safety systems, and data transmission.

  • Example 1: Printed touch-sensitive dashboards reduce mechanical components, but wire harnesses are still needed for steering, engine, and powertrain connections.
  • Example 2: Transparent, flexible defrosters are embedded in windshields, yet reliable wiring is required for heating and power circuits.

2. Aerospace & Aviation

While printed sensors can help monitor aircraft structures, critical avionics, navigation, and control systems still rely on strong, fail-safe wire harnesses.

  • Example 1: Boeing and NASA use printed antennas to reduce weight, but primary avionics still depend on high-quality wire harnesses.
  • Example 2: Flexible sensors monitor structural integrity, but all essential flight control and communication systems require shielded wiring for safety.

3. Industrial IoT & Smart Factories

Factories are getting smarter with printed sensors, but automation systems, heavy machinery, and high-speed data connections require wire harnesses for uninterrupted operation.

  • Example 1: Printable humidity and gas sensors are used for monitoring, but machine power lines and safety circuits still depend on wire harnesses.

4. Medical & Wearable Devices

Wearable devices benefit from flexible electronics for biosensors and patches, but critical medical devices like MRI and CT scanners still need wire harnesses for power and high-speed data transmission.

  • Example 1: Printed ECG patches monitor heart activity, but hospital imaging machines require high-quality cable assemblies and shielding.

Why Wire Harnesses Aren't Going Anywhere

While flexible and printed electronics bring exciting innovations, they have their limits. Here's why wire harnesses are still indispensable:

  • Power Handling Limitations: Printed electronics work at low voltages. Wire harnesses are essential for high-voltage power distribution in EVs, aerospace, and industrial settings.
  • Durability & Environmental Resistance: Printed circuits can be vulnerable to moisture, wear, and electromagnetic interference. Shielded wire harnesses are built to last, even in extreme conditions.
  • Integration with Legacy Systems: Many industries still rely on wired infrastructure, so complete replacement isn't realistic. Hybrid solutions allow for smoother integration without sacrificing reliability.

The Future: Hybrid Systems with Wire Harnesses & Flexible Electronics

The goal isn't to replace wire harnesses but to make them smarter and more efficient while integrating emerging technologies.

  • Wire harnesses will remain the backbone of high-power and mission-critical applications.
  • Printed electronics will complement harnesses in low-power, lightweight, and aesthetic-focused applications.
  • Advanced software solutions will optimize wire harness design, seamlessly integrating new technologies.

Conclusion: The Growing Need for Smart Wire Harness Software

The future isn't about eliminating wire harnesses but enhancing them with better design, smarter integration, and cutting-edge software solutions. As industries adopt new technologies, the need for intelligent wire harness design software will only grow. Companies that leverage advanced design, optimization, and integration tools will gain a real competitive edge in the evolving landscape of electronics and connectivity.

Wire harnesses aren't going anywhere—they're evolving to support smarter, more connected systems.

Want to design wiring for your harness seamlessly? Experience the power of wire harness design in Altium Designer!

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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