In 2023, the market size of automotive wiring harnesses in China reached 107.03 billion RMB, with a year-on-year growth of 31.39%. It is projected to exceed 120 billion RMB by 2025. The share of wiring harnesses for new energy vehicles (NEVs) has surged from 4.8% in 2019 to 62.5% (approximately 75 billion RMB) by 2025, becoming the primary growth driver.
The widespread adoption of 800V platforms has driven the voltage rating from 600V to over 1500V. The global high-voltage wiring harness market is expected to reach 18 billion USD by 2025, with China accounting for 45%. Key technological breakthroughs include liquid cooling designs and three-layer electromagnetic shielding (copper braid + aluminum foil + absorptive layer).
A wiring harness manufacturer in Hubei Province achieved a 100% increase in output value in the first half of the year through intelligent transformation. Without increasing labor costs, the company realized sales of 180 million RMB and a production capacity increase of over 30%.
High Voltage and High-Frequency Transmission Technology
Energy Transmission: High-voltage cables need to support currents over 400A. The cross-sectional area of the conductors has increased from 35mm² to 70mm². The plating on connectors is shifting from gold to silver-nickel alloys to reduce resistance.
Signal Transmission: L3+ autonomous driving has led to the adoption of automotive
Ethernet Cables (with a bandwidth of 10Gbps), replacing traditional CAN buses. In some models, using an Ethernet backbone reduces the length of wiring harnesses by 40% and latency by 60%.
Breakthroughs in Lightweight Materials and Processes
Aluminum Replacing Copper: Aluminum wires have 97% of the conductivity of copper, are 30% lighter, and cost 40% less. Nanocoating technology addresses the issue of aluminum oxidation, with an expected application rate of 22% by 2025.
Structural Optimization: Carbon fiber composite sheaths and thin-wall insulation technology (with a wall thickness of 0.1mm) reduce the weight of wiring harnesses by 60%, increasing the vehicle's range by 5-10%.
Intelligent Manufacturing and Modular Design
Automation Upgrade: AI quality inspection and machine vision have reduced defect rates from 0.5% to 0.1%. By 2025, the automation rate in domestic factories is expected to reach 75%, reducing labor costs by 40%.
Modular Revolution: Some automotive platforms have reduced the number of connector types from 120 to 30, increasing assembly efficiency by 25%. High-end electric vehicle models have shortened the total length of wiring harnesses to 100 meters, a reduction of 77%.
03Acceleration of Localization: Breaking the 70% Foreign Monopoly, Market Share Surges
While global market CR3 (Japanese and American giants) holds 71% of the market, the market share of Chinese domestic enterprises has risen from 3% to 28%. Leveraging advantages such as 40% lower costs and a 30% shorter response cycle, these companies have entered the supply chains of international automakers.
New Automakers Become Key to Breakthrough:
Local new car manufacturers prefer regional supply chains, reducing customized development cycles from 12 months to 8 months. The Yangtze River Delta industrial cluster covers 50% of the national demand, ensuring delivery resilience.
Collaborative Industry Chain in Response to Challenges:
Fluctuations in Raw Material Prices: Copper prices account for 65%-80% of costs. Companies mitigate the pressure on gross margins through futures hedging and the use of aluminum as an alternative.
Low-Carbon Transition: New EU regulations require a wire harness recycling rate of over 95%. The application of bio-based materials reduces the carbon footprint by 60%.
