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Designing wiring harnesses – the invisible engineering that keeps vehicles working .

While most automotive systems get the spotlight – engines, batteries, infotainment – it’s the humble wiring harness that truly connects them all. In an age of electrification, autonomy, and high-speed data, wiring harnesses are becoming more complex and mission-critical than ever.

Rapid market growth fuelled by EVs & data 

The global wiring harness market is expanding rapidly to support rising vehicle electrification and digitalisation. In 2025, the market is estimated to be between USD 67 billion and USD 90 billion, driven by advanced driver-assistance systems (ADAS), infotainment, and high-voltage electric vehicle systems. Analysts expect it to double by 2035, growing at a compound annual growth rate (CAGR) of 6 – 7%. 

Asia-Pacific leads the deployment of harness systems, representing nearly 48% of the market in 2024, while the HVAC and high-voltage segments are growing fastest, with a CAGR of 11%, reflecting their importance in EV architectures. 

Engineering challenges behind the scenes 

Harness design is far from simple. Engineers must balance: 

  • Electrical performance: Supporting high-voltage power lines and high-speed data buses,
  • Mechanical reliability: Withstanding thermal and vibrational stresses, 
  • Manufacturability & modularity: Ensuring cost-effective production in lean and automated workflows.

AI is making its mark – now helping optimise harness routing, reduce weight, and automate connector placement. Robotics and vision systems are even planning for automated connector mating, a breakthrough in reducing manual assembly errors. 

Endego’s capabilities in Wiring Harness engineering  

From the definition provided on our Wiring Harness Competence page, Endego brings deep, real-world expertise in designing and implementing wiring harness systems: 

  • Comprehensive development of wiring harness architecture – from concept through to production readiness,
  • Detailed electrical and mechanical design, including shielding, connector placement, and stress resistance,
  • Support for high-voltage and data-critical systems, ensuring reliability under real-world conditions,
  • Seamless integration into vehicle layouts, considering assembly constraints, serviceability, and mass optimisation.

These services are offered through flexible delivery models, including Talent-as-a-Service (TaaS), Solution Delivery, and Build-Operate-Transfer (BOT), ensuring alignment with client team structures, development timelines, and scalability needs. 

Why Wiring Harnesses are central to Next-Gen vehicles 

  1. Safety & compliance: High-voltage events in EVs carry additional regulatory scrutiny, especially for insulation and fire-retardant design.
  2. Vehicle performance: Automotive innovations – like 48-volt systems, zonal architectures, and high-speed data – depend on robust, precise wiring.
  3. Manufacturability: As Industry 4.0 takes hold, harnesses must support automated installation and quality traceability.
  4. Cost & weight optimisation: Innovative routing, modular design, and material selection enhance efficiency and reduce waste.

The wiring harness is the invisible backbone of every vehicle’s electrical system. As software-defined architectures, electrification, and connectivity transform mobility, wiring design is gaining the engineering spotlight. 

Endego’s blend of deep architecture skills, engineering precision, and development flexibility empowers OEMs and Tier-1 suppliers to deliver harness systems that meet tomorrow’s performance, safety, and cost requirements. 

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Sources: 

  • Future Market Insights – Automotive Wiring Harness Market Outlook (2025, CAGR 6.4%) 
    https://www.futuremarketinsights.com/reports/global-automotive-wiring-harness-market
     
  • GlobeNewswire – Automotive Wiring Harness Market to Reach USD 125.3B by 2035 
    https://www.globenewswire.com/news-release/2025/02/17/3027180/0/en/Exploring-the-Growth-of-the-Automotive-Wiring-Harness-Market-USD-125-3-Billion-by-2035-Future-Market-Insights-Inc.html 
  • Precedence Research – Automotive Wiring Harness Market Size 2025–2034 
    https://www.precedenceresearch.com/automotive-wiring-harness-market 
  • ArXiv – AI-based Framework for Connector Mating in Robotic Harness Installation 
    https://arxiv.org/abs/2503.09409 

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