The automotive cable industry is entering a dynamic transformation phase, propelled by increasing vehicle electrification, evolving regulatory frameworks, and heightened technical demands.

While traditional ICE (Internal Combustion Engine) vehicles continue to require complex wiring systems, the rise of electric mobility—spanning BEVs, PHEVs, FCEVs, and advanced hybrids—is dramatically increasing both the demand and technical requirements for cables in the automotive sector.

Growth forecast for the automotive wires and cables market

The global high‑voltage automotive wires and cables market is expected to reach approximately USD 25.3 billion by 2030, growing at a CAGR of 14.9%.

These figures illustrate a consistent upward growth trajectory driven by electrified propulsion systems. In fact, according to MarketsandMarkets®, the global EV cables market was valued at USD 8.6 billion in 2023, and is projected to grow to USD 19.0 billion by 2028, representing a compound annual growth rate (CAGR) of 17.2%

Increasingly high fuel prices, strong R&D efforts by EV cable makers, and expanding EV charging infrastructure in emerging markets are key drivers boosting this expansion.

 

Drivers and market forces

Electrification of vehicle fleets

Electric vehicles (EVs) are radically transforming the transport sector, redefining the automotive market, and reshaping global trade in transport equipment. By the end of 2023, EVs accounted for more than a third of all car imports in value terms.

In 2023, electric car sales nearly surpassed 14 million units globally, representing a 35% year-on-year increase with 3.5 million more sales compared to 2022.

As vehicles become more electric, the content of high-voltage cabling increases substantially, driven by powertrain requirements and battery management systems.

Charging infrastructure expansion

The data provided by UNECE reveals a gradual yet notable growth in Direct Current (DC) recharging points, marking a shift toward faster, high-power solutions.

This trend generates a demand for robust, heat-resistant, and flexible charging cables.

Technological innovation

The need for higher voltage capacity (up to 1 kV DC and beyond), improved thermal stability, electromagnetic shielding, and reduced weight mandates the adoption of advanced insulation materials (XLPE, EPR, TPE) and lightweight conductors like aluminum or hybrid variants.

Recent market trends indicate a shift towards high-temperature Cross-linked Polyethylene (XLPE) cables due to their superior electrical performance and ability to operate under increased temperature conditions. Moreover, the Ethylene Propylene Rubber (EPR) is also expected to witness a steady growth rate due to its superior flexibility, resistance to ozone and UV radiation, and low moisture absorption properties.

 

EVs regional market analysis

The market’s expansion exhibits notable regional variations, each defined by specific policy frameworks and industrial capacity.

The Asia Pacific EV market is projected to reach USD 326.5 Billion by 2030, at a CAGR of 6.9%. China’s EV demand continues to grow rapidly, with domestic automakers expanding their global presence. Its leadership in production technology and battery recharging infrastructure, and favorable government regulations such as establishing far-flung charging networks allows it to lead the way in innovation for EV. Likewise, India plays a crucial role thanks to strong government support and heavy investment by OEMs.

In Europe challenges are intensifying, threatening the EV trajectory and weigh on established carmakers.

Benefitting from stringent emission targets and a planned phase-out of ICE vehicles by 2035, it is expected to witness significant growth in the < 125 MPH segment of the EV market by 2030 owing to the presence of key market players in the region, such as Volkswagen AG, BMW Group, and Stellantis.

North America’s EV market size is projected to grow at a CAGR of 10.0% from 2025 to 2030. This growth can be attributed to supportive government policies and incentives, such as tax credits and rebates, to make EVs more affordable for consumers.

 

The evolution of automotive cables: from new specifications to smarter, lighter, safer designs

Automotive cables are evolving rapidly to meet the demands of electrification, advanced driver assistance systems (ADAS), and connected mobility.

Therefore, cable manufacturers require increasingly sophisticated production technology and up-to-date technical standards, materials, and designs.

Shift from Copper to Aluminum and Advanced Alloys

Even though copper has a long history as the material of choice for conducting electricity, the pursuit of weight reduction in electric and hybrid vehicles is driving a shift toward aluminum conductors and specialty alloys.

In fact, Aluminum Cable for Automotive Application Market size is estimated to be USD 1.2 Billion in 2024 and is expected to reach USD 2.5 Billion by 2033 at a CAGR of 9.1% from 2026 to 2033. This happens because aluminum has 61 percent of the conductivity of copper, but has only 30 percent of the weight of copper, making it ideal for EV. Furthermore, the development of new alloys and extrusion techniques has enhanced the performance of aluminum cables, making them more competitive against traditional copper wiring.

Despite this, copper remains essential for critical low-resistance and high-density applications, especially in sensor and signal harnesses.

Multi-Layer Insulation for high volts and harsh environments

The modern cable must endure up to 1,000 V DC, extreme temperatures, vibration, and electromagnetic interference. As a result, multi-layer insulation systems are now standard, so that the insulation of the cable does not deteriorate due to the high-voltage stress, ozone produced by electric discharges in air, or tracking featuring:

• XLPE or EPR for robust high-voltage insulation;
• TPE, fluoropolymers, or bio-based jackets for environmental protection; 
• copper or aluminum shielding to ensure electromagnetic compatibility (EMC).

These complex constructions enhance dielectric strength, thermal performance, and mechanical durability. Manufacturers are responding with precision co-extrusion lines capable of micron-level thickness control and rapid material changeover.

Integration of power, data, and sensor lines

With connected and autonomous vehicles, harnesses must carry a blend of high-voltage power, sensor leads, data lines (e.g., CAN‑FD, Ethernet), and diagnostics. It’s increasingly common to see hybrid cables combining power conductors with shielded data pairs or fiber-optic strands .

These integrated assemblies support real-time monitoring and ADAS functions, simplifying installation and reducing weight. Additionally, optical or twisted-pair segments lessen EMI risk and improve bandwidth in automated vehicle communication networks.

This trend requires modular extrusion and bundling systems that can precisely combine diverse cable types in a single line.

 

Key technical requirements driving change

To fully encapsulate these trends, automotive cables now must meet several core technical criteria:

• Voltage capacity up to 1,000 V DC, withstanding breakdown and leakage under real-world stress.
• Thermal endurance, retaining integrity across –40 °C to +150 °C or higher.
• Flexibility and bending resilience, particularly for dynamic applications and vibration-prone zones.
• Reliable EMC shielding, maintaining signal fidelity amidst high-power electronics.
• Lightweight materials, helping vehicles meet efficiency and emission goals.

Meeting these requirements demands precision extrusion, advanced shielding machines, and real-time quality control embedded in production.

 

The process of producing EV and automotive cables

Manufacturing high-performance automotive cables involves a carefully orchestrated sequence of advanced processes, each essential to meet the stringent requirements of modern vehicles.

Below is a structured overview of the typical production process:

1. Drawing (copper or aluminum)
2. Annealing
3. Stranding (Note for EVs: High-frequency applications may require special stranding to reduce skin effect and improve efficiency)
4. Extrusion: PVC, XLPE (cross-linked polyethylene), TPE, TPU for automotive; HFFR (halogen-free flame retardant), silicone, or fluoropolymers for EVs.
5. Laying up / Twisting
6. Sheathing (Special needs for EVs: Flame resistance, low smoke emission, chemical resistance, and thermal performance up to 150°C or more.)

 

How MFL Group supports automotive cable manufacturers

At MFL Group, we bring over a century of experience to every stage of the automotive cable production chain—drawing, stranding, extrusion, and treatment—enhanced by advanced digitalization and dedicated services.

The process typically begins with rod breakdown. Our portfolio includes the TS1, a single- or dual-wire machine with up to 15 blocks on one level, designed for high output and excellent cable quality, real 1% slip, energy-efficient operation, and outstanding wire quality.

Alternatively, the TS2 features 15 blocks arranged over two levels, combining compact design, combining compact design, real 1% slip, energy-efficient operation, and high wire quality.

From there, wires are processed through a multiwire drawing line running at speeds up to 35 m/s, handling up to 48 wires (24 per row) with 15–33 dies. The MFL design allows to reduce downtime, energy use, and maintenance—boosting overall efficiency.

Next, our double twist stranding machines deliver high compaction rates and productivity, ensuring superior cable performance.

Insulation is handled by high-speed extrusion lines reaching up to 1,500 m/min. Optimized for HFFR and LSOH materials, they minimize scrap and allow rapid color changes (main, skin, or stripe). They are also compatible with PVC, PE, XLPE, PPE, TPE, and PP.

To meet the rising demands of e-mobility, our lines also support insulation with Polyether Ether Ketone (PEEK). This high-performance material offers exceptional dielectric properties, chemical resistance, and continuous operation up to 240°C—making it ideal for EV cables rated up to 1,000 volts.

After insulation, our single twist machines, with options for direct pull or independent rotating capstans and/or our double twist machines ensure consistent laying-up.

Finally, the sheathing line accommodates both round and non-round power cables across a wide range of materials, from PVC to EPDM. MFL extrusion line design, across all sections ensures stable operation—whether for standard sheathing or advanced co-extrusion and tandem setups.

 

EV cable manufacturing demands precision, reliability, and adaptability. With our broad machinery portfolio, energy-efficient technologies, and dedicated expertise, MFL Group stands as your all-around partner, helping manufacturers deliver high-performance automotive cables that meet the industry’s toughest standards.

Contact us to find out how we can support and enhance your EV cable production.

Source:

• High-Voltage Automotive Wires and Cables market size, share, trends, dynamics, forecast, & growth analysis 2024-2030 (www.stratviewresearch.com)
• EV Cables Market by Type, Voltage, EV application, High voltage application, insulation, shielding type, component and region – global forecast to 2028; Electric Vehicle Market Size, Share & Analysis (www.marketsandmarkets.com)
• EV Cables Market worth $19.0 billion by 2028 – Exclusive Report by MarketsandMarkets™ (www.marketsandmarket.com)
• Trade data reveal changing patterns in electric vehicles market (www.wto.org)
• North America Electric Vehicles Market Size, Share & Trends Analysis Report (www.grandviewresearch.com)
• Copper vs. Aluminum Conductors (www.anixter.com)
• Global Aluminum Cable for Automotive Application Market Size (www.verifiedmarketreports.com)
• Trends in electric cars (www.iea.org)
• A Look Across EV Recharging Infrastructure in UNECE Countries (w3.unece.org)