Next-Gen EV Harnesses: Lightweight Conductors and Overmolded Safety
Introduction
The shift to electric mobility is accelerating at an unprecedented pace. Global EV sales surpassed 14 million units in 2023, and OEMs are doubling down on electrification platforms. But beneath every sleek, battery-powered silhouette lies a critical system that keeps the vehicle functional, efficient, and safe: the EV wiring harness. As these vehicles become more complex, with higher voltage demands and smaller packaging spaces, harnesses must evolve rapidly.
Two technologies are leading this evolution: lightweight conductors, which optimize energy efficiency and performance, and overmolded safety systems, which enhance durability and reliability in high-voltage environments. This blog explores how Celestix Industries, a custom wiring harness manufacturer, is pushing the boundaries of both technologies to help OEMs engineer the future of e-mobility.
Why Weight Reduction Is Critical in EV Wiring Harnesses
EV range is directly impacted by vehicle mass. Every kilogram saved contributes to increased range or allows for downsized battery packs, reducing both cost and environmental impact. Traditional copper conductors, while excellent in conductivity, are heavy. Celestix addresses this with aluminum EV conductors and hybrid aluminum-copper alternatives to deliver lightweight EV wire harness solutions.
Key Benefits of Lightweight Harnesses
These lightweight options also support modular vehicle design, helping OEMs standardize components across vehicle lines, improving time-to-market, and simplifying inventory.
Optimizing for Weight and Performance
Celestix's lightweight HV wiring solutions are not just about using less material. Our designs optimize wire gauge selection, conductor bundling, and insulation thickness to balance thermal efficiency, flexibility, and strength. This precision ensures that lightweight doesn’t come at the cost of durability or compliance.
Engineering Challenges Addressed
Thermal regulation in tightly packed spaces
Mechanical fatigue due to vehicle vibrations
Electromagnetic interference (EMI) in high-voltage layouts
Routing constraints in compact EV platforms
By solving these challenges through smarter material and design choices, we enable next-gen EV harnesses to meet the demands of modern vehicle architecture.
Engineering Considerations: Aluminum-Copper Hybrid Conductors
While aluminum is up to 40% lighter than copper, it presents challenges such as lower tensile strength and higher contact resistance. Celestix mitigates these by employing copper-clad aluminum (CCA) for an optimal balance of weight and performance.
Benefits of Hybrid Conductors
Up to 30% weight reduction
Cost-effective material sourcing
Sufficient conductivity for power circuits
Celestix Engineering Controls
Crimp Profile Analysis: Verified after every setup change
Corrosion Prevention: Sealed interfaces and overmolding
Thermal Expansion Management: Advanced routing and spacing techniques
3D FEA Analysis: Applied during mechanical simulation and layout verification
Lightweight harnesses require optimized EV cable bending radius, which we validate with 3D simulations to prevent fatigue over the vehicle lifecycle. These simulations are validated in our in-house testing lab, replicating worst-case temperature cycles and mechanical stresses.
The Role of Overmolding in EV Harness Safety
Environmental exposure, vibration, and high-voltage risks demand advanced protection. Overmolding techniques EV encapsulate wire junctions and connectors in durable thermoplastics to enhance performance.
Benefits of Overmolded Cable Assemblies
Sealing: Meets IP67/IP68 ratings
Shock Resistance: Vibration and impact protection
Space Efficiency: Cleaner packaging of complex branches
Strain Relief: Reduces connector stress and pull-out risk
EMI Protection: Supports shielding of high-frequency signal cables
Common Overmolding Materials
Celestix uses precision-engineered molds and automated injection systems to ensure repeatability in every batch. These overmolded cable assemblies also integrate RFID tracking, smart diagnostics ports, and tamper-proof seals for enhanced field service.
Built for Compliance: High-Voltage EV Safety and Testing
Celestix manufactures high-voltage wiring harnesses with built-in compliance from design to delivery. Every harness is tested under real-world conditions in our in-house lab.
Compliance and Testing Protocols
100% in-process and final QC
High-Pot Testing: 1000V + 2x rated voltage
Dielectric Strength: >3kV
EMI Shielding: Across signal and power lines
Color Coding: International orange insulation for HV compliance
Standard Test Matrix
These protocols meet and exceed certifications including:
IATF 16949 certified harnesses
ISO 9001 wire harness standards
UL and CE certifications
Industry Applications: Where It All Comes Together
Our automotive wiring harness systems are already used in:
Electric SUVs and commercial EVs
Battery Management Systems (BMS)
Onboard Chargers (OBC)
Traction inverter motor lines
Rapid-charge and V2G interface systems
Use Case: A leading two-wheeler EV OEM in India reduced weight by 18% and saved 11% on total BOM cost by switching to Celestix’s aluminum overmolded assemblies.
Why Celestix?
As a trusted wire harness manufacturing India partner, Celestix offers:
Scalable capacity for 5–6x annual growth
In-house lab and overmolding capability
Flexible for low or high volume needs
Located in Pune, India, globally shipping
Committed to the DRIVE Culture: Dedication, Respect, Integrity, Value, Excellence
We are not a reseller. We are a manufacturer with hands-on engineering teams, IPC-certified assembly technicians, and automated QC infrastructure.
Ready to Upgrade Your EV Harness Platform?
Let Celestix help you build safer, lighter, and brighter EVs.
Take the Next Step
Request a Custom Quote – Our engineers will review your specs and deliver tailored harness solutions.
Schedule a Consultation – Connect with our technical experts for guidance on your EV platform needs.
Email Directly: info@celestixindustries.com – Start your sourcing discussion with our team.
Celestix Industries – Proven, certified, and trusted for next-generation EV wiring harnesses engineered for global mobility.
Looking for a reliable manufacturing partner for your EV platform? Celestix delivers innovation, compliance, and quality at every step. Contact us today to explore how we can support your next project.
