Global Electric Vehicle Wiring Harness Market 2022-2027

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    • Electric vehicles require the installation of additional high-voltage lines for AC-DC charging, high-voltage batteries, and traction, as well as special wiring for the high-voltage battery and the battery management system.
    • Growth of ADAS technology, connected driving and infotainment features in a car are the drivers of electric vehicle wiring harness industry 
    • In 2021, the average wiring harness per vehicle was 13 kg in Argentina, 18 kg in Italy, 20 kg in Japan, and more than 25 kg in the UK.
    • Wiring harness technology will shift toward more environmentally friendly, EV-specific, high-speed data communication-oriented, and consolidated terminals and junctions, resulting in a more compact wiring harness network.
    • Autonomous vehicles will improve the demand for electric vehicle wiring harness due to increased communication between various systems in a vehicle.
    • Many automobile manufacturers have already switched to aluminium for large cables used with batteries and other applications requiring anything larger than 10 gauge.
    • OEMs are likely to eliminate the 3-phase cables for power transmission due to the trend of  integrating the power electronics directly into electric motors
    • Due to rising environmental concerns and copper prices, auto OEMs and wiring harness manufacturers are focusing on more sustainable solutions to improve wiring harness quality and reusability.
    • Marelli has launched a wireless distributed battery management system that reduces wiring harness by 90%, allowing for greater flexibility, efficiency, reliability, and cost reductions in electric vehicles.
    • In May 2022, Lucid Motors has issued a recall for its Air EV related to the Ethernet wiring harness for its 34-inch, curved 5K Glass Cockpit instrument panel


    An electric drivetrain of an HEV or EV consists of a wide variety of electronics such as high-voltage battery and motors. They are connected by high-voltage wiring harness for power transfer.


    A wiring harness is an organized set of wires, terminals and connectors that run through the vehicle and relay information and electric power, thereby connecting a variety of components. Power and information travel through this delicate network.


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    The wiring harness in the vehicle is one of the heaviest and most expensive individual parts of a car (after the engine and transmission). In addition, the vast range of variants of today’s vehicle models requires a tailor-made cable system for almost every possible configuration as there is considerable change in various systems from vehicle to vehicle


    Electric vehicles require additional expensive high-voltage lines for AC-DC charging, high-voltage batteries and, traction as well as special wiring for the high-voltage battery and the battery management system. GM is bringing about wireless battery management system in their new electric vehicle platform Ultium.


    To know more about Global Automotive Wiring Harness Market, read our report



    The changes in vehicle electronics will also result in a variety of changes in cable and cable channels:

    • Introduction of a more centralized computer architecture with powerful domain computers instead of dozens of distributed ECUs
    • increased use of sensors with correspondingly higher data volumes within the vehicle and between the vehicle and the outside world, as well as the electrification of the drive train


    In future data-driven business models which is gaining traction right now across manufacturers, some functions may only be temporarily enabled via OTA software updates.


    In the case of electric vehicles, this can also include the motor performance. For car manufacturers to be able to implement such functions, the cabling must be designed for the maximum possible performance, even if this is rarely required at all due to the uncertainty of usage and also preparing for shifts in business models at any time

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    In addition to energy recovery and some other auxiliary technology, the bigger battery is the car’s important design ideas, so proper body layout, sufficient interior space, and apt safety features also put forward a higher design requirement. Soft, high bending radius of the wiring harness on the compact installation space is particularly important.


    Thin-walled wire is a good choice for improving the softness of the wiring harness and reducing the space occupied by the wiring harness. However, compared with the thick insulation wall wire, its wear resistance, temperature and pressure resistance will achieve a higher performance claim.


    Performance check for electric wire harness

    • high temperature
    • low temperature
    • anti-aging performance
    • Resistance to liquids (gasoline, diesel, coolant, battery acid, etc.)
    • Insulation is easy to age after contact with the oil short-circuit is also more and more cases confirmed by the accident.


    Harness passes through many areas where it requires protection against heat, dust, moisture etc. Wire harness protection prevents damage caused by wire vibration damage, abrasions and incidental contact with other pieces of heat-producing equipment.


    Thermal management tubes and sleeves are designed to operate under high temperatures and provide fire resistance under extreme conditions. The tubes and sleeves must be difficult to ignite, and they must self-extinguish promptly. The most common types of cable and wire protection are

    • braided sleeving
    • corrugated loom
    • heat shrink
    • vinyl tubing
    • conduit


    A typical wiring harness drawing has cable lengths, component view, grommet, connector specifications and inline connectors.


    Up until this point, the Leoni simulation process had difficulty keeping up with the number of iterations required to determine the ideal location for our harnesses. Design Space Exploration, the main component of this new strategy, employs an optimization algorithm to repeatedly approach the best harness design in a pre-specified space.


    They have accelerated their procedures to be completed in less than 24 hours thanks to this new strategy, giving them more time to align with clients on data quality.


    The use of a simulation toolchain is already integrated into routine business operations. It covers a broad range of tasks, including electrical wire dimensioning for harnesses, designing mechanical components and their structures, placing and cooling electronics PCBs properly, and designing injection tooling to assure proper moulding procedures.


    Additionally, they have begun the dynamical simulation of certain important harness routing, such as door and trunk opening, driveline and axle connection, etc. The objective is to guarantee the proper performance and eliminate any chance of clinch, break, etc. by ensuring the suitable positioning and qualities, such as harness length.


    A precise grasp of the various cables to model serves as the foundation for the cable simulation. In order to extract all cable parameters based on laser measurement and with high accuracy, such as bending qualities, LEONI has invested in a characterisation device called Mesomics.


    The cable simulation models that will be used in projects can be tailored using these parameters, which are integrated into the database.


    Engineers will route the harnesses according to guidelines and their own experience in a project using the 3D mechanical design and environment to simulate tensions and bending radius.


    An derived fatigue index from the simulation is shown as a traffic light to draw attention to unsafe circumstances. Up until a suitable routing is reached, changes to the fixation points, length, etc., will be evaluated iteratively.


    To know more about Global EV Connector Market, read our report





    Governor , state and local officials, and representatives from Adopt a Charger and electric car manufacturer Rivian celebrated the opening of the first of about 15 electric vehicle charging stations that will be set up in Michigan state parks and a state fish hatchery over the coming few years close to the lovely, sandy beaches of Lake Michigan at Holland State Park.


    At the 142-acre state park in Ottawa County, four Rivian Waypoints chargers were inaugurated. An inaugural charge that included a Rivian R1T truck followed.


    This collaboration to provide charging stations in state parks demonstrates the teamwork we are using to boost our economy and combat climate change head-on with clean, dependable energy.


    According to an operating agreement between Adopt a Charger and the Michigan Department of Natural Resources, Rivian, an electric vehicle manufacturer and automotive technology firm, will provide open-network, Level 2 Rivian Waypoints chargers at no cost to the state or taxpayers.



    The Global Electric Vehicle Wiring Harness Market is a small derivative of the automotive wiring harness market. In 2021, the market size was estimated at $XX Million growing at –% CAGR till 2027.




    Suppliers in western Ukraine have been shuttered by the Russian invasion, forcing them to limit output, and carmakers such as Volkswagen, BMW, and Porsche are battling to secure critical wire harnesses.


     The item, which is used to organise kilometres of vehicle wires, has impacted vendors such as Leoni, Fujikura, and Nexans, as well as major carmakers. Some assembly plants of World No. 2 carmaker Volkwagen have already experienced delivery problems, while Porsche’s premium division has halted production at its Leipzig factory. 


    BMW, a competitor, has also been impacted. Our manufacturing will be disrupted due to supply shortages, BMW warned in a statement.


    In the ordinary car, a wire harness is a critical combination of components that neatly bundles up to 5 kilometres of cables. Vehicles cannot be created without them because they are unique to each automobile model. 


    Suppliers such as Leoni, which has two wire harness manufacturers in western Ukraine, are scrambling to make up for production losses and disruptions in two plants in Stryi and Kolomyja, which have been sparked by Russia’s action against Ukraine.


     Leoni stated that a task team had been constituted to assess the situation. Suppliers such as Germany’s Forschner, Kromberg Schubert, Prettl, SEBN, and Japan’s Yazaki have built up a sizable wire harness production sector in Ukraine, which also has a competent workforce, to lower prices and better compete in the global automotive industry.


    Automotive businesses have invested in plants, with many, but not all, making wire harnesses, according to UkraineInvest, the Ukrainian government’s investment promotion bureau. 


    These plants are adjacent to automotive factories in Germany and multinational carmakers’ manufacturing hubs in central Europe. According to industry sources, increasing capacity at alternative sites in suppliers’ networks might take months, requiring factory space, machinery and tools, people, and money. 


    Aptiv Plc, an auto components manufacturer, spent months doing just that before the invasion, transferring high-volume production of car parts out of its two Ukrainian sites ahead of probable hostilities.




    The California firm partnered with WeWire for its first vehicle model, the Lucid Air, in the wire harness industry. Wewire’s engineers were able to create prototypes of the necessary parts in a record-breaking six weeks.


    Here, the ability of WeWire to create specialized and, more importantly, lightweight plastic mounts, was key. Thus, the Lucid Air is the first electric vehicle to be fully outfitted with mounts made of plastic that was created in-house by WeWire.


    A factory for car wiring harnesses will be built in Guatemala by Yazaki North America Inc., a manufacturer of automotive components. The new facility will be built in Guatemala’s San Marcos Department’s municipality of Ayutla.


    The majority of automakers, including several in the developing electric mobility industry, are supplied by Yazaki. Additionally, the company is extending its business portfolio in telematics and energy systems.







    1. Electric Vehicle Wiring Harness Market size and Forecast, by region, by application
    2. Average B-2-B price for Electric Vehicle Wiring Harness Market, by region, per user
    3. Technology trends and related opportunity for new Electric Vehicle Wiring Harness Market tech suppliers
    4. Electric Vehicle Wiring Harness Market share of leading vendors, by region,
    5.  Coronavirus impact on Electric Vehicle Wiring Harness Market earnings
    Sl no Topic
    1 Market Segmentation
    2 Scope of the report
    3 Abbreviations
    4 Research Methodology
    5 Executive Summary
    6 Introduction
    7 Insights from Industry stakeholders
    8 Cost breakdown of Product by sub-components and average profit margin
    9 Disruptive innovation in the Industry
    10 Technology trends in the Industry
    11 Consumer trends in the industry
    12 Recent Production Milestones
    13 Component Manufacturing in US, EU and China
    14 COVID-19 impact on overall market
    15 COVID-19 impact on Production of components
    16 COVID-19 impact on Point of sale
    17 Market Segmentation, Dynamics and Forecast by Geography, 2022-2027
    18 Market Segmentation, Dynamics and Forecast by Product Type, 2022-2027
    19 Market Segmentation, Dynamics and Forecast by Application, 2022-2027
    20 Market Segmentation, Dynamics and Forecast by End use, 2022-2027
    21 Product installation rate by OEM, 2022
    22 Incline/Decline in Average B-2-B selling price in past 5 years
    23 Competition from substitute products
    24 Gross margin and average profitability of suppliers
    25 New product development in past 12 months
    26 M&A in past 12 months
    27 Growth strategy of leading players
    28 Market share of vendors, 2022
    29 Company Profiles
    30 Unmet needs and opportunity for new suppliers
    31 Conclusion
    32 Appendix


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