Automotive Secondary Wiring Harness Market - Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Vehicle Type (ICE and EV), By Application (Cabin, Door Harness, Engine Harness, Airbag Harness, Electronic Parking Brakes and Electronic Gear Shift System), By Regional, By Competition 2021-2031F

Forecast Period	2027-2031
Market Size (2025)	USD 21.37 Billion
CAGR (2026-2031)	10.01%
Fastest Growing Segment	Engine Harness
Largest Market	Asia Pacific
Market Size (2031)	USD 37.88 Billion

Market Overview

The Global Automotive Secondary Wiring Harness Market will grow from USD 21.37 Billion in 2025 to USD 37.88 Billion by 2031 at a 10.01% CAGR. The Global Automotive Secondary Wiring Harness Market consists of auxiliary electrical distribution systems designed to transmit power and data to peripheral vehicle components, such as infotainment units, door modules, lighting, and sensors, distinct from the primary chassis architecture. This market is primarily driven by the exponential increase in electronic content per vehicle, the adoption of decentralized zonal electrical architectures, and the electrification of powertrains which requires specialized sub-assemblies. Illustrating this robust demand for vehicle inputs, according to the Automotive Component Manufacturers Association of India (ACMA), in 2024, the auto-components industry turnover expanded by approximately 10%, fueled by strong vehicle production volumes and export growth.

However, a significant challenge impeding market expansion is the volatility of raw material costs, particularly copper and specialized polymers, coupled with supply chain fragility. Manufacturers face intense pressure to reduce harness weight and cost while navigating these input fluctuations and global logistical disruptions. This instability is further exacerbated by the unpredictable pace of the electric vehicle transition in certain regions, which complicates long-term capital investment and production planning for specialized component suppliers, potentially stalling steady industry growth.

Key Market Drivers

The surging adoption of electric and hybrid vehicles serves as a primary catalyst for the secondary wiring harness sector. Unlike internal combustion engines, electrified powertrains require extensive auxiliary low-voltage cabling to support battery management systems, regenerative braking controls, and thermal regulation units. This shift necessitates specialized harnesses that can withstand higher thermal loads while minimizing weight to preserve range efficiency. As manufacturers transition product lines, the volume of these peripheral electrical subsystems has expanded significantly to accommodate the unique architecture of new energy platforms. Validating this upward trend, according to the International Energy Agency (IEA), April 2024, in the 'Global EV Outlook 2024', almost 14 million new electric cars were registered globally in 2023, bringing the total number on the roads to 40 million. This substantial rise in fleet numbers directly correlates to increased procurement of specialized secondary power distribution assemblies required to manage complex electrical inputs.

Concurrently, the integration of advanced infotainment and connectivity systems is reshaping wire harness architecture. Modern vehicles are evolving into digital cockpits featuring multiple high-definition displays, sensor arrays for parking assistance, and always-on 5G modules, all of which demand complex secondary data transmission networks. According to LG Electronics, January 2024, in the 'Earnings Release Q4 2023', the Vehicle component Solutions company achieved its highest annual revenue of KRW 10.1 trillion, driven by the growth of in-vehicle infotainment and e-powertrain products. This proliferation of cabin electronics compels manufacturers to utilize thinner, flexible, and more durable wiring solutions to fit within tighter spaces. Furthermore, reflecting the broader financial momentum in this sector, according to Aptiv PLC, in 2024, the company reported record full-year revenue of $20.1 billion for the previous year, highlighting the sustained commercial appetite for advanced signal distribution technologies.

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Key Market Challenges

Material cost volatility, specifically regarding copper and specialized polymers, acts as a substantial barrier to the stability of the Global Automotive Secondary Wiring Harness Market. These secondary systems rely heavily on conductive metals and durable insulation, making manufacturers highly vulnerable to price fluctuations that erode profit margins. When input costs rise unexpectedly, suppliers struggle to maintain competitive pricing structures without compromising the quality or weight reduction targets demanded by automakers. This financial uncertainty complicates long-term production planning and discourages the capital investment necessary for expanding facilities or developing specialized sub-assemblies for electrified powertrains.

The impact of this economic pressure is evident in recent industry sentiment regarding supply chain dynamics. According to the European Association of Automotive Suppliers (CLEPA), in 2024, 77% of automotive suppliers reported significant difficulties in passing on cost increases to vehicle manufacturers, while 60% expected a decrease in revenues due to these persistent pressures. This inability to transfer rising material costs downstream forces harness manufacturers to absorb losses, directly hampering their ability to sustain steady market growth or fund the innovation required for decentralized zonal architectures.

Key Market Trends

The adoption of Zonal Electronic Architectures Reducing Secondary Harness Lengths is fundamentally restructuring vehicle power and data distribution networks. By replacing domain-centralized layouts with zone controllers located physically closer to sensors and actuators, manufacturers can significantly shorten wire lengths and consolidate circuits, thereby minimizing the complexity and weight of the physical cabling. This architectural shift simplifies the integration of harnesses into space-constrained chassis and supports the software-defined vehicle ecosystem by separating input/output management from compute functions. Highlighting the commercial traction of this technology, according to Aptiv PLC, February 2024, in the 'Fourth Quarter 2023 Earnings Call', the company secured $5.2 billion of customer awards specifically for its Smart Vehicle Architecture solutions during the prior year, reflecting a rapid industry transition toward these optimized topologies.

Increased Automation in the Manufacturing of Standardized Secondary Sub-Harnesses is emerging as a critical response to rising labor costs and stringent quality requirements. While traditional harness assembly is highly manual, the move towards modular designs allows suppliers to deploy automated machinery for cutting, crimping, and assembling sub-components, effectively reducing human error and production time. This operational pivot improves margin stability and enables scalability for high-volume production programs that require precise repeatability. Validating the financial impact of these efficiency measures, according to Lear Corporation, February 2025, in the 'Fourth Quarter and Full Year 2024 Results', the company's E-Systems segment revenue outperformed global industry volume by 6 percentage points, a performance directly attributed to strategic investments in its 'IDEA by Lear' automated manufacturing capabilities.

Segmental Insights

The Engine Harness segment currently demonstrates the most rapid expansion within the Global Automotive Secondary Wiring Harness Market. This growth is primarily driven by the automotive industry’s shift toward electrification, which demands complex wiring configurations for battery management and electric drivetrains. Furthermore, strict emission standards enforced by global regulatory bodies compel manufacturers to integrate additional sensors and electronic control units into vehicle powertrains. This rising electronic density requires durable harnesses to facilitate precise signal transmission and system reliability. As a result, the engine harness remains essential for operational efficiency and regulatory compliance, fueling its accelerated market demand.

Regional Insights

Asia Pacific dominates the Global Automotive Secondary Wiring Harness Market, driven by its status as the world’s largest automotive production hub. The region benefits from massive manufacturing scales in China, Japan, and India, where rising consumer purchasing power is accelerating the adoption of vehicles equipped with electronic amenities. This demand for features like infotainment, power seats, and advanced safety sensors directly increases the need for complex secondary wiring assemblies. Additionally, the region's aggressive transition toward electrification further boosts market expansion. Industry data from the China Association of Automobile Manufacturers confirms the sustained high production volumes that underpin this regional leadership.

Recent Developments

• In July 2025, Leoni AG underwent a significant change in its corporate structure as Luxshare-ICT secured majority ownership of the company. This strategic development followed an agreement that was approved by regulatory bodies earlier in the year. The acquisition by the Chinese electronics manufacturer was designed to strengthen Leoni's competitive position in the global automotive wiring systems market. By integrating with Luxshare’s extensive manufacturing capabilities, Leoni aimed to enhance its production efficiency and expand its footprint in key regions, ensuring a robust supply chain for its secondary and main wiring harness solutions.
• In January 2025, Aptiv PLC announced a definitive plan to separate its Electrical Distribution Systems business into an independent, publicly traded company. The Board of Directors unanimously approved this spinoff to create a standalone entity focused exclusively on high-voltage and low-voltage signal, power, and data distribution solutions. This strategic move allowed the new company to concentrate its resources on the specific needs of the automotive wiring harness market, including secondary harnesses for complex vehicle architectures. The separation was intended to unlock greater value for shareholders and enable the new entity to pursue targeted growth strategies in the evolving mobility sector.
• In July 2024, Lear Corporation highlighted a major contract win during its second-quarter financial reporting, confirming it had been awarded the low-voltage wiring business for the Volvo EX30 in Europe. This achievement underscored the company's growing influence in the secondary wiring harness segment, which handles critical auxiliary functions in modern electric vehicles. Alongside this commercial success, the company completed the acquisition of WIP Industrial Automation to bolster its manufacturing capabilities. These initiatives reflected the company's commitment to leveraging advanced automation and securing key partnerships to meet the rising demand for sophisticated electrical distribution systems.
• In May 2024, Yazaki Corporation and Toray Industries, Inc. jointly revealed a breakthrough in sustainable materials for the automotive wiring harness market. The companies collaborated to develop a recycled polybutylene terephthalate (PBT) resin grade specifically designed for manufacturing connectors used in vehicle wire harnesses. This innovative material utilized scrap materials from manufacturing processes, significantly reducing carbon dioxide emissions without compromising the performance or durability required for automotive applications. The collaboration demonstrated a focused effort by major industry players to introduce circular economy principles into the production of essential secondary harness components.

Key Market Players

• Aptiv PLC
• Yazaki Corporation
• Furukawa Electric Co. Ltd.
• THB Group
• Spark Minda, Nexans
• Samvardhana Motherson Group
• Leoni AG
• Sumitomo Electric Industries Ltd.
• Lear Corporation
• Ashok Minda Group

By Vehicle Type	By Application	By Region
ICE and EV	Cabin Door Harness Engine Harness Airbag Harness Electronic Parking Brakes and Electronic Gear Shift System	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global Automotive Secondary Wiring Harness Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

• Automotive Secondary Wiring Harness Market, By Vehicle Type:

• ICE and EV

• Automotive Secondary Wiring Harness Market, By Application:

• Cabin
• Door Harness
• Engine Harness
• Airbag Harness
• Electronic Parking Brakes and Electronic Gear Shift System

• Automotive Secondary Wiring Harness Market, By Region:

• North America
• United States
• Canada
• Mexico
• Europe
• France
• United Kingdom
• Italy
• Germany
• Spain
• Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• South America
• Brazil
• Argentina
• Colombia
• Middle East & Africa
• South Africa
• Saudi Arabia
• UAE