Starway Industry Insights

Top 10 Global Wiring Harness Industry Developments

September 17 to September 28, 2026

Overview

From mid to late September 2026, the global wiring harness and electrical interconnect industry continued to move toward modular architectures, automated assembly, lighter conductors, high voltage power distribution, and advanced charging systems. Key themes included zonal vehicle architecture, rigid and flexible busbar integration, automated sub harness processing, aluminum conductors, high speed automotive data links, regional manufacturing, recyclable insulation materials, energy storage cabling, high voltage interlock testing, and liquid cooled charging cables.

Key Takeaways

1. Zonal architecture and busbar integration

Zonal electrical architecture and integrated busbar systems can reduce cable length and overall harness mass while simplifying vehicle assembly.

2. Automated sub harness assembly

Crimping, electrical testing, connector loading, and wrapping are increasingly being combined into automated production cells.

3. Materials and standards

Aluminum conductors, recyclable insulation materials, and updated high voltage testing methods continue to raise requirements for process control and validation.

1. Aptiv and zonal controller harness production

Aptiv announced production activity for wiring modules designed for central computing and zonal vehicle architectures. The approach reduces long vehicle wide cable runs by moving electrical connections closer to local control zones.

Starway perspective

Zonal architectures divide large harnesses into smaller local modules. During new product introduction, manufacturers should control branch length, connector position, routing clearance, and assembly tolerance to support accurate final installation.

2. Sumitomo Electric and high voltage busbar automation

Sumitomo Electric expanded automated manufacturing for high voltage busbars and specialized harness products used in electric powertrain and charging applications. The production concept combines shaped copper and aluminum conductors with automated assembly for high voltage systems.

Starway perspective

When round high voltage cables are replaced by shaped busbars, manufacturers should verify insulation quality, spacing, shielding continuity, dielectric performance, and low resistance electrical joints.

3. Komax and Leoni and automated modular harness assembly

Komax and Leoni presented automated processes for modular sub harness production. The process combines terminal crimping, electrical continuity checks, connector loading, and wrapping into a more integrated production flow.

Starway perspective

Automated sub harness manufacturing depends on stable wire, terminal, and connector specifications. For high mix and low volume projects, flexible tooling and validated work instructions remain important during the transition from prototype builds to larger production runs.

4. Yazaki and aluminum high voltage conductors

Yazaki advanced high voltage harness solutions that use aluminum alloy conductors and specialized joining and sealing methods. The objective is to reduce conductor weight while maintaining electrical and mechanical reliability during temperature cycling.

Starway perspective

Aluminum conductor systems require careful control of oxidation, galvanic interaction, terminal joining, and environmental sealing. Process monitoring and validated sealing methods are important for long term reliability.

5. TE Connectivity and automotive high speed data links

TE Connectivity introduced automotive optical fiber and shielded data cable solutions for advanced driver assistance and automated driving systems. These products are designed to support high data rates between sensors, cameras, and vehicle computing systems.

Starway perspective

High speed data cables require consistent stripping dimensions, shield coverage, connector assembly, and impedance control. Production validation should include suitable electrical or optical inspection methods.

6. Motherson and regional manufacturing expansion

Motherson expanded wiring harness manufacturing capacity in Monterrey, Mexico, with a focus on commercial vehicle, chassis, and electrified vehicle applications.

Starway perspective

Regional manufacturing can improve delivery response and engineering coordination. Contract harness manufacturers can support customers through flexible production, engineering changes, and local inventory planning.

7. Lear and recyclable insulation materials

Lear introduced halogen free thermoplastic elastomer insulation concepts for automotive harness applications. The material direction supports heat resistance and improved recyclability compared with some conventional insulation systems.

Starway perspective

New insulation materials should be validated for abrasion resistance, electrical performance, stripping quality, tooling compatibility, and joining process stability before volume production.

8. Amphenol and energy storage power harnesses

Amphenol Industrial introduced a standardized DC power distribution harness concept for utility scale battery energy storage systems. The design focuses on sealed connectors, outdoor durability, and modular installation.

Starway perspective

Energy storage harnesses operate in demanding outdoor environments. Manufacturers should verify terminal resistance, sealing performance, electrical insulation, and process traceability for reliable long term service.

9. ISO and SAE and high voltage interlock testing

ISO and SAE published revised guidance related to high voltage interlock behavior under vibration and thermal cycling. The work places increased attention on contact stability and long term connector performance in high voltage vehicle systems.

Starway perspective

High voltage interlock testing should consider both static continuity and intermittent contact behavior under vibration. Terminal retention and contact stability should be included in the validation plan.

10. Furukawa Electric and liquid cooled charging cables

Furukawa Electric advanced liquid cooled cable assemblies for high power commercial vehicle charging applications. The concept combines electrical power transmission with an internal cooling path to manage cable temperature during heavy current operation.

Starway perspective

Liquid cooled charging cables combine electrical assembly with fluid sealing requirements. Manufacturing therefore requires coordinated control of terminal joining, pressure testing, leak inspection, and cable assembly quality.

Manufacturing Framework

Specification review

Confirm electrical load, operating temperature, bend radius, shielding needs, and environmental requirements.

Bill of materials review

Verify the specified wire, terminal, connector, insulation, and accessory materials.

Prototype and tooling

Build reference samples and suitable fixtures to identify routing, clearance, and assembly risks before production.

Process control

Control crimp dimensions, pull force, joining parameters, and operator work instructions.

Electrical testing

Perform continuity, insulation, and other required electrical checks with appropriate lot traceability.

Engineering FAQ

How does zonal vehicle architecture affect wiring harness manufacturing

Zonal architecture shifts the focus from large vehicle wide harnesses toward smaller local modules. Manufacturing priorities therefore move toward precise short wire processing, compact connector assembly, modular testing, and consistent installation tolerances.

Why are high voltage systems adopting busbars and liquid cooled cables

High current systems need to manage conductor size, packaging, temperature, and weight. Busbars and liquid cooled cable concepts can improve packaging efficiency while supporting higher electrical loads.

How does Starway Technology support advanced harness projects

Starway Technology focuses on custom and high mix low volume interconnect projects. During new product introduction, the manufacturing process can include specification review, prototype builds, process validation, electrical inspection, and documented quality control.

Contact

Customers may provide drawings, bills of materials, pin assignments, connector part numbers, and operating requirements for engineering review. Starway Technology can support technical evaluation, prototype builds, and production planning.