Integrating harness design within electric vehicle architecture

As electric vehicles (EVs) continue to reshape the automotive landscape, one area of design has grown significantly in complexity and strategic importance: the electrical architecture.

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Once seen as a passive component in traditional combustion vehicles, the wiring harness in EVs has become a highly engineered system that supports not just power distribution, but also data communication, thermal safety, and regulatory compliance. As EV platforms evolve toward higher voltage levels, greater modularity, and more software-defined functionality, harness design must evolve alongside them.

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This article explores the role of electrical harnesses in EVs, the challenges they introduce, and the innovations transforming how these systems are developed.

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Understanding electrical harnesses in EVs

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An electrical harness is a structured assembly of wires, connectors, terminals, and protective elements that carries both power and signals throughout the vehicle. In electric vehicles, this system becomes even more complex, as it must:

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• Safely carry high-voltage currents from the battery to inverters, motors, and auxiliary systems
• Transmit low-voltage signals between sensors, control units, and software-defined features
• Withstand thermal, mechanical, and electromagnetic stresses
• Fit within increasingly compact and integrated vehicle architectures

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Modern EVs require wiring harnesses that can handle voltages up to 800V, manage dynamic loads, resist EMI (electromagnetic interference), and maintain reliability across extreme environmental conditions.

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Why harness design is so complex in EVs

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The move from internal combustion engines (ICE) to electric powertrains has introduced new design constraints that make harness planning more difficult, and more critical:

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High power density

Unlike ICE vehicles, EVs rely on a centralized energy source (the battery pack) to supply all systems. High-current cables must be routed safely, often in limited space, while maintaining insulation and thermal separation.

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EMI and signal integrity

With so many software-controlled systems and sensors onboard, signal integrity is a top priority. Harnesses must be designed to minimize electromagnetic interference while preserving communication reliability between electronic control units (ECUs).

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Mechanical integration

Modern EVs feature more integrated chassis, battery enclosures, and thermal systems. Harnesses must route cleanly through these elements, avoiding pinch points, sharp edges, and areas with excessive vibration.

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Compliance and safety

Global EV regulations require strict attention to high-voltage safety. Harnesses must meet standards for insulation resistance, IP sealing, crash performance, and thermal runaway containment.

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Packaging and assembly

Space is at a premium in most EV platforms, and harnesses must be optimized not just for function, but also for efficient assembly and future serviceability. Complex routing must be made repeatable on the production line.

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Tools and technologies transforming harness design

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The growing complexity of electric and electronic systems in modern vehicles has pushed traditional harness design tools to their limits. In response, a new wave of technologies is reshaping how engineers approach routing: 3D modeling environments, rule-based validation systems, and simulation-driven design platforms now allow teams to anticipate constraints earlier, reduce errors, and ensure compliance from the start.

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These advancements are making it possible to move away from manual, drawing-based workflows and toward more intelligent, system-aware routing processes. Engineers can now evaluate mechanical integration, electromagnetic compatibility, and thermal interactions within the same digital environment—saving time and enabling better decision-making across disciplines.

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Within this evolving landscape, Dessia offers a unique and powerful solution.

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Instead of relying solely on manual routing or post-hoc validation, Dessia leverages augmented intelligence to help engineers generate optimized routing scenarios—whether for electrical harnesses, ducts, or fluid lines—constrained by engineering rules. These can include bend radius, straight segment requirements, clearance from surrounding geometry, or even attachment and clipping logic.

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By embedding routing intelligence directly into the design process, Dessia allows teams to iterate faster, explore alternatives with confidence, and ensure that every route complies with the physical and functional constraints of the system. This AI-driven approach not only improves design quality—it helps teams build more scalable, modular architectures from day one.

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Discover how Dessia can help optimize your design processes and accelerate innovation - Get in touch with our experts

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Looking ahead

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As vehicles become increasingly electrified, connected, and software-defined, the complexity of harness design will only continue to grow. But so will the tools.

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We’re entering an era where AI agents and rule-based design engines will no longer serve as one-time generators, but as collaborative tools that continuously interact with engineering intent. Instead of waiting for human input, these AI agents will help identify routing conflicts, suggest optimized paths based on real-time changes, and validate compliance against evolving constraints—across mechanical, electrical, and thermal domains.

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Harness routing will shift from being a manual task to a strategic layer of system integration, governed by logic, adaptable to change, and fully embedded in the product development pipeline.

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This shift will open the door to highly scalable, modular harness architectures that are easier to adapt across platforms, easier to maintain, and more robust by design.

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Discover how Dessia can help optimize your design processes and accelerate innovation - Get in touch with our experts

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