Automotive Wiring Harness Market

[374 Pages Report] The global automotive wiring harness market size was valued at USD 48.7 billion in 2023 and is expected to reach USD 59.5 billion by 2030, at a CAGR of 2.9%, during the forecast period 2023-2030. The automotive wiring harness market has shown significant growth recently. Top OEMs are investing in the same, which would further drive the demand for high-speed data transmission wiring harnesses. Though the need for electronic features is growing in Europe and North America, Asia Pacific remains the key market.

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Market Dynamics

DRIVER: Rise in Advanced Features in Vehicles

The automotive industry is witnessing a growing emphasis on safety and security, driving the demand for driver-assist technologies like Adaptive Cruise Control (ACC), Blind-Spot Detection (BSD), Advanced Front Lighting (AFL), and Lane Keeping Assist (LKA) to incorporate advanced features into vehicles. ACC systems rely on radar and sensors to maintain a safe following distance from the vehicle in front. Advanced parking systems, including 360-degree cameras and proximity sensors, rely on wiring harnesses to transmit data to the vehicle’s infotainment screen or instrument cluster, aiding drivers during parking maneuvers. All these systems require wiring harnesses to transfer data from the sensors to the vehicle’s steering system. Also, the surge in consumer demand for advanced features in vehicles is a significant driving factor behind the growth of the automotive wiring harness market. To meet these expectations, automakers are incorporating intricate electrical and electronic components in modern vehicles, increasing the dependency on wiring harnesses. The rise of electric and hybrid vehicles further amplifies this demand, with specialized wiring harnesses becoming pivotal for battery management, powertrains, and charging infrastructure. Moreover, the increasing integration of the Internet of Things (IoT) in vehicles and the need for customization and adherence to stringent regulations has driven the need for more complex and adaptable wiring solutions. As a result, automotive wiring harnesses are pivotal components in the evolving automotive industry, facilitating the safe and efficient operation of these advanced features, ultimately enhancing the driving experience and safety for consumers.

Additionally, there is a mandate for vehicle manufacturers to comply with safety regulations, such as the Bharat New Vehicle Safety Assessment Program (BNVSAP), which requires the inclusion of passive safety features. For example, India mandated the standard fitment of driver-side and front passenger-side airbags in new models starting in April 2021. Similarly, the US National Highway Traffic Safety Administration (NHTSA) expects automatic emergency braking systems to become standard in vehicles by 2022. Furthermore, integrating multimedia and security systems has driven up the installation of cables and wiring harnesses. Comfortable features, including voice recognition systems, ambient lighting, heated seats, and advanced infotainment functionalities, have gained popularity among consumers, enhancing the overall driving experience. These features rely on onboard electronic devices that communicate through control signals powered by the vehicle’s electrical system, necessitating wiring harnesses. The increasing complexity of vehicle designs, aligned with advanced features, has led to a higher demand for wiring harnesses, consequently propelling the growth of the automotive wiring harness market.

The advanced features, such as voice recognition systems, ambient lighting, heated seats, heated steering wheels, enhanced infotainment functionality, digital instrument panel displays, cooled cupholders, and additional power steering functions, have gained significant traction among consumers. These rely on electronic devices that require wiring harnesses to transfer data, signals, and power efficiently. Within automotive design, wiring harness bundles are essential for the seamless operation of these diverse functionalities. Moreover, using active safety systems in vehicles has become instrumental in minimizing accidents, leveraging onboard sensors, radar, cameras, GPS, and laser technology. Notable active safety systems encompass Anti-lock Braking Systems (ABS), Electronic Stability Control (ESC), Electronic Brake-Force Distribution (EBD), Tire Pressure Monitoring Systems (TPMS), Lane Departure Warning Systems (LDWS), Automatic Emergency Braking (AEB), Blind-Spot Detection (BSD), Forward Collision Warning (FCW), and Traction Control Systems. The integration of these advanced features demands an ever-increasing number of wiring harnesses, propelling the growth of the automotive wiring harness market.

RESTRAINT: Limited data transfer rate

The growing complexity of modern vehicles, with their numerous advanced features, sensors, and connectivity options, necessitates high-speed and high-capacity data transfer. Limited data transfer rates can impede the performance of various vehicle systems, including infotainment, advanced driver-assistance systems (ADAS), and connected car features. As vehicles evolve with autonomous driving capabilities and increased connectivity, fast and reliable data transfer demand becomes even more critical. There are various advanced features in vehicles, such as a reverse parking camera, tire pressure monitoring system, and anti-lock braking system, which require the cabling from the camera to the electronic control unit (ECU) as there is no alternative to transfer the data. The traditional wiring harness can achieve a data transfer rate of up to certain kbps, and advanced features in the vehicle require high-speed data transfer in Mbps or Gbps.

The companies are moving from traditional copper wiring harnesses to high-strength aluminum, high-speed twisted pair cables, and optical fiber cables to gain high-speed data rates. Companies like Bosch provide CAN FD solutions. Data rates for CAN FD can vary but may reach up to 5 Mbps or more. Companies like Broadcom, Marvell, and NXP Semiconductors provide Ethernet solutions for automotive use. Ethernet can offer data rates of 100 Mbps, 1 Gbps, or even 10 Gbps, depending on the implementation. There are different networks integrated into vehicles, such as CAN, LIN, CAN-FD, FlexRay, MOST (Media Oriented Systems Transport), and LDS (Low Voltage Differential Signaling), which transfer the data in wing-mirrors, powered seats, ambient lighting, various high-performance powertrain applications such as active suspension, adaptive cruise control, drive-by-wire, camera, and other infotainment applications.

The limited data transfer rates are anticipated to affect automotive wiring harness market growth adversely. However, there is a growing interest in incorporating fiber optic technology into modern vehicles, especially as the demand for high-speed data transmission, connectivity, and advanced driver assistance systems (ADAS) continues to rise. Some luxury and high-end vehicles already feature fiber optic networks for infotainment and communication systems. For instance, Mercedes-Benz S-Class models feature a fiber optic-based infotainment system, offering high-quality audio and connectivity options. BMW 7 Series offers advanced infotainment and connectivity features. Some models incorporate fiber optic networks to support high-definition audio and multimedia systems. Companies like Sumitomo Electric Industries Ltd., Leoni AG, and Aptiv PLC have products offering high-speed data transfer technology to meet the demand.

OPPORTUNITY: Increase in use of high voltage wiring harnesses and optical fiber cables

The rise in electric and hybrid vehicles has necessitated the adoption of high voltage wiring harnesses to efficiently manage the flow of electrical power within these vehicles. High voltage wiring harnesses are vital for connecting the battery packs, power inverters, and electric motors, enabling the reliable operation of these electrified powertrains. As the market for electric vehicles continues to expand, the demand for specialized high voltage wiring solutions is expected to surge.

High-voltage cables are a significant advancement in power transmission compared to traditional copper wires of the same size. The amount of power a cable can handle is directly linked to its voltage level, meaning higher voltage cables can carry much more power. For instance, a 100 kV cable can transport 100 times the power of a 1 kV cable. Importantly, these high-voltage cables are more powerful, lighter, and robust than their copper counterparts. Their reduced weight aligns with the ongoing trend of making electric vehicles (EVs) lighter. Moreover, their durability makes them an excellent choice for demanding automotive environments.

In electric vehicles (EVs), optical fiber cables are being used to transmit data between different parts of the vehicle. These cables offer some key advantages over the traditional copper wires. They have a higher data capacity, meaning they can transfer more information quickly. They are also not affected by electromagnetic interference, which can disrupt data transmission in high-tech automotive settings where many electronic systems and sensors are at work nearby. Additionally, optical fiber cables are lighter, contributing to the goal of making EVs more lightweight and efficient. This makes them a great choice for modern, technology-packed cars. The PMMA-based graded-index plastic optical fiber can achieve a maximum bandwidth of approximately 3 GBPS when spanning 100 meters. While fiber optics offer several advantages, such as high data transfer rates, immunity to electromagnetic interference, and potential weight savings, the automotive industry traditionally relies on copper wiring for its electrical and data transmission needs. ABB Ltd., Cable Corporation of India Limited., Finolex Cables Ltd., Nexans SA., NKT A.S., Prysmian SpA., Siemens AG., and Southwire Company LLC. are some companies producing high-voltage automotive cables.

With the growing adoption of BEVs, the demand for high voltage wiring harnesses will also increase, further driving the automotive wiring harness market. Global battery electric vehicle sales increased from 14,23,000 units in 2018 to 67,67,716 units in 2022. Increasing battery electric vehicle sales would have a direct impact on the market for automotive wiring harnesses. Companies like Furukawa, Sumitomo Electric Industries Ltd., Leoni AG, and others have also developed high voltage wiring harnesses and are working on improving these cables.

CHALLENGE: Fluctuating copper costs due to increasing demand

The automotive industry heavily relies on copper for manufacturing wiring harnesses. Copper is an excellent conductor of electricity and is widely used in wiring due to its reliability and conductivity. Copper is preferred for wiring harnesses due to its favorable characteristics, including ease of assembly, compact bundle size, high electrical conductivity, flexibility, and reliability. However, the pricing of copper can be a significant challenge due to fluctuations driven by supply and demand imbalances.

The global demand for copper greatly influences its price, making it susceptible to continual increases. While copper and its alloys are versatile and widely used in various applications, many wiring harness manufacturers use aluminum as an alternative due to its lightweight and cost-effectiveness. Aluminum’s lower conductivity necessitates larger wire sizes for the same power rating. Additionally, aluminum requires specific termination technology to overcome challenges such as galvanic corrosion, oxidation, aging-related deformation, high thermal expansion, and lower flexibility and tensile strength. Consequently, copper remains the primary choice for wiring harness applications, although its fluctuating prices can impact the profitability of manufacturers. Moreover, the automotive industry has witnessed an increase in the use of copper per vehicle, particularly in regions like China, where the average copper weight per vehicle grew from 10.3 kg in 2016 to 14 kg in 2019. This increasing usage of copper in vehicles further exacerbates the impact of copper price fluctuations on automotive wiring harness costs, posing a challenge for manufacturers.

Additionally, the unstable copper prices have repercussions for the market of optical fiber cables. Original Equipment Manufacturers (OEMs) consider optical fibers a more durable alternative to copper or aluminum, capable of withstanding harsh environments and adverse weather conditions. However, optical fiber cables are relatively more expensive, potentially limiting their adoption. Furthermore, the expanding electric vehicle (EV) market is expected to influence copper demand considerably over the coming decade. A study conducted by the International Copper Association (ICA) in collaboration with IDTechEx revealed the crucial role of copper in various aspects of EV technology, from batteries and electric motors to wiring and charging infrastructure. The increasing adoption of EVs, driven by technological advancements, cost-efficiency, and a growing electric charger infrastructure, is anticipated to substantially increase copper demand. It is projected that by 2027, the number of electric vehicles on the road will increase to an estimated 27 million, up from 3 million in 2017, leading to a significant surge in copper demand, expected to reach 1.74 million tons in 2027.

Automotive Wiring Harness Market Ecosystem

The ecosystem analysis highlights automotive wiring harness market players, primarily represented by component manufacturers, manufacturers, and dealers.

The chassis harness segment is estimated to be the largest market during the forecast period.

The Chassis harness segment is estimated to be the largest during the forecast period. The chassis of a vehicle is a central hub for various electrical components and systems, including those related to steering, braking, suspension, and stability control. Chassis wiring harnesses connect and interlink these components, which can be complex. As vehicles become more advanced with features like electronic stability control, adaptive suspension systems, and advanced braking systems, the complexity of chassis wiring increases. In Asia Pacific, the chassis wiring harness market is projected to hold the largest share during the forecast period in terms of value. The application of chassis wiring harnesses is expected to increase in Asia Pacific due to the increasing number of buses and trucks in the region. Increasing number of commercial vehicles in developing countries and growth in the ecommerce industry are major drivers of the chassis wiring harness market.

The electrical wiring harness market in ICE vehicles is anticipated to dominate based on transmission type.

Electrical wiring harnesses are fundamental vehicle components, connecting and supplying power to various electrical and electronic systems. These harnesses ensure the efficient and reliable operation of a wide range of vehicle functions, including lighting, power distribution, safety systems, infotainment, and more, and facilitate the operation of critical components, systems, and features, contributing to vehicle safety, performance, and functionality. They are used for transferring signals and power within the vehicle. According to primary respondents, electrical wiring accounts for almost 75-80% of the share in wiring harnesses by value. The predominance of electrical wiring harnesses is driven by modern vehicles’ increasing complexity and electrification, which require extensive and intricate electrical systems to support advanced features and functionalities. Ongoing developments focus on improving performance, reducing weight, and meeting environmental standards. Electrical wiring harness design holds paramount significance in vehicle engineering and performance. Primarily, it ensures the vehicle's safety by connecting crucial components like airbags and brake lights, preventing electrical malfunctions that could lead to accidents. Asia Pacific has the largest market share in electrical wiring due to increasing vehicle connectivity and functions. With advancements in technology, the number of tasks in a vehicle is expected to grow further.

The motor management harness is the fastest-growing segment in the high-voltage wiring harness segment.

High voltage wiring harnesses are crucial in motor management within electric vehicles (EVs) and hybrid electric vehicles (HEVs). These components transmit high-voltage electricity between various parts of the vehicle’s electrical system, including the power source (usually a high-voltage battery) and the electric motor or motors responsible for propulsion and energy regeneration. The demand for high-voltage systems has surged as the automotive industry continues to shift towards greater electrification, encompassing electric and hybrid vehicles. High voltage systems, including electric motors, power inverters, and battery management systems, are integral to electrified powertrains.

EVs and HEVs use electric motors to power the vehicle, and the MMS is responsible for controlling the operation of these motors. As more and more people switch to EVs and HEVs, the demand for MMS harnesses is expected to continue to grow. Companies like TE Connectivity, Yazaki Corporation, Sumitomo Electric Industries, Ltd., etc., are developing high voltage wiring harnesses that are designed to meet the needs of electric vehicles (EVs), hybrid electric vehicles (HEVs), and plug-in hybrid electric vehicles (PHEVs). For instance, Guchen Electronic provides a drive motor high-voltage wire harness, a vital link between the electric motor and the high-voltage battery pack in electric vehicles. Crafted with premium components and dual insulation, this wiring harness offers excellent electrical properties, including robust insulation resistance and high current-carrying capacity, supporting currents of up to 300A. Sumitomo Electric has also introduced two innovative products in response to evolving trends in electric vehicles, one of which is designed as a direct connector that enables the seamless connection between the inverter and motor through high-voltage connectors.

Asia Pacific is the largest-growing market in the automotive wiring harness market.

The study scope considers the Asia-Pacific region comprising countries - China, India, Japan, South Korea, Thailand, and the Rest of Asia-Pacific. In 2023, the Asia-Pacific region accounted for a 58% share of the global automotive wiring harness market in value. Increased vehicle production in China, India, and Japan contributed to the market’s growth. China was also the major contributor to the overall automotive wiring harness sales (approximately 55%) in the Asia-Pacific region in 2023.

During the forecast period, China is estimated to dominate the Asia-Pacific automotive wiring harness market. China is the world’s largest vehicle manufacturer. Thus, China’s market is estimated to grow faster. As electric vehicles require more wiring harnesses than traditional vehicles. China has one of the world’s largest and fastest-growing automotive markets, driven by an expanding middle class, and increasing urbanization. The demand for passenger cars in China has been on the rise, leading to increased production by both domestic and international automakers. The number of middle-class households in China is expected to reach 550 million by 2025. This growth in the automotive market of China drives the need for sophisticated and high-quality wiring harnesses in the country. During the forecast period, Japan is estimated to be the second-largest market for the Asia Pacific market. The growth in Japan is primarily propelled by increasing demand for light passenger vehicles and heavy-duty vehicles and the growing demand for electric vehicles. In addition to high export and import, factors such as increasing Gross Domestic Product (GDP), infrastructure investments, rising per capita income, growing inclination toward comfort and levisure, and government initiatives for FDI have created more opportunities for containerized business, in turn driving the market in the Asia Pacific region.

Key Market Players

The automotive wiring harness market is led by established players, such as Yazaki Corporation (Japan), Sumitomo Electric Industries (Japan), Aptiv PLC (Ireland), Furukawa Electric (Japan), and Leoni AG (Germany). These companies have adopted several strategies to gain traction in the market. They have expanded in various geographical locations through mergers & acquisitions and expansions and entered joint ventures/collaborations with other industry players to sustain their position in the market.

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Scope of the Report

Along with the given market data, MarketsandMarkets offers customizations in accordance with the company’s specific needs

The study segments the automotive wiring harness market :

ICE, By Application:

• Engine harness
• Chassis wiring harness
• Body & lighting harness
• HVAC harness
• Dashboard/ cabin harness
• Battery harness
• Seat harness
• Sunroof harness
• Door harness

EV, By Application

• Traction harness
• Engine harness
• Chassis wiring harness
• Body & lighting harness
• HVAC harness
• Dashboard/ cabin harness
• Battery harness
• Seat harness
• Sunroof harness
• Door harness

By Component

• Connectors
• Terminals
• Wires
• Others

By Material type

• Metallic
  • Copper
  • Aluminum
  • Other Materials
• Optical fiber
  • Plastic optical fiber
  • Glass optical fiber

By Transmission type

• Electrical wiring
• Data transmission

Data transmission harness market by data transfer rate

• <150 Mbps
• 150 Mbps to 1 Gbps

By High Voltage Wiring Harness

• Battery and battery management system
• Motor management harness

By Region

• Asia Pacific
• North America
• Europe
• Rest of the World [RoW]

Recent Developments

• In May 2023, Sumitomo Electric and NICT (National Institute of Information and Communications Technology) developed the world’s first 19-core optical fiber with a standard outer diameter. They set a new world record for transmission capacity. The new fiber can transmit 1.6 terabits per second (Tbsp.) over 10,000 kilometres, which is twice the capacity of the previous record holder. The development of this new fiber is a breakthrough for long-distance optical communication and is expected to be used in future 5G and beyond 5G networks.
• In May 2023, Sumitomo Electric Wiring Systems will invest approximately USD 10 million in manufacturing harnesses, becoming the first Tier 1 automotive company to establish operations in Tabasco, Mexico. Tabasco has seen a remarkable 24.3% growth in economic activity, positioning itself as an attractive destination for automotive investment. The company will be located near key transportation routes in the Tabasco Business Center industrial park.
• In March 2022, Morocco’s Ministry of Industry and Trade has inked eight investment agreements with prominent international automotive suppliers like Yazaki, Sumitomo, Lear, Stahlschmidt, and TE Connectivity, totalling USD 175 million in investments and promising the creation of 12,000 direct jobs. Yazaki Group has entered into three agreements for substantial investments in Morocco’s automotive sector. This includes the construction of a new wiring production plant in Meknes and expanding existing facilities in Kenitra and Tangier.
• In December 2022, Aptiv PLC successfully acquired an 85% equity stake in Intercable Automotive Solutions from Intercable S.r.l., with the deal valued at USD  627 MN. Intercable Automotive Solutions, a leader in high-voltage power distribution and interconnect technology, will be an independent business unit under Aptiv’s Signal & Power Solutions segment, maintaining its existing brand. This acquisition strengthens Aptiv’s global leadership in vehicle architecture systems.
• In June 2022, Furukawa Electric secured deals with eight automakers to use its aluminium wire harnesses in one hundred vehicle models by 2025, mainly targeting European automakers. The company will continue developing aluminium harnesses to further reduce weight as the global shift toward EVs accelerates.

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