The challenges of miniaturisation in EV design and how to overcome them

4th March 2024  |  Electric vehicle

The miniaturisation of electronics in electric vehicles (EVs) brings a number of benefits. They free space for larger batteries, enable emergency vehicles to carry more equipment and help in maximising driving range through lightweight components.

However, EV miniaturisation brings its own range of challenges, particularly in the realms of temperature management and corrosion resistance. In this article, we will explore these challenges before explaining how high-quality components can help in overcoming them.

Challenges of EV miniaturisation


One significant challenge arising from miniaturisation is the increase in internal temperature. As components become smaller, their transistor and energy densities increase. This concentration of energy in a compact space leads to higher operating temperatures within the vehicle. These temperatures need to be managed and minimised as excessive heat can impair component performance as well as negatively affect battery lifespan and performance.


Another challenge of miniaturisation is the increased risk of corrosion, particularly fretting corrosion with contactor components. As contactors get smaller, there are a greater number of small contact points between components. This directly increases the risk of fretting corrosion where moisture is present in a high vibration environment, eventually leading to breaks in the vehicle circuit if left unchecked.

High-performance component solutions for EVs

To overcome these challenges, the EV industry relies heavily on high-performance components that aid in thermal management and corrosion resistance. Modern connector and cable assembly solutions are designed to meet these needs as well as the electrical and mechanical requirements of EVs.

Connector – High-quality connectors are engineered to offer thorough corrosion resistance and thermal management to efficiently dissipate heat away from critical components. They have a shielding design to prevent moisture building between the contactor surfaces and easily dissipate thermal buildup. Moreover, they help minimise the impact of vibrations that can accelerate fretting wear and corrosion.

Cable assemblies – Cable assemblies are engineered with heat-resistant materials and protective coatings, which shield them from high temperatures and prevent corrosion. These features ensure the assemblies maintain integrity and performance in harsh conditions, protecting the internal wiring from external environmental threats.

TE Connectivity – high performance for miniature design

A leader in the development of high-performance connectors and cable assemblies is TE Connectivity. TE Connectivity’s range of products is specifically designed to meet the rigorous demands of the EV industry. Their connectors and cable assemblies are renowned for their durability, reliability, and ability to withstand harsh environmental conditions, including extreme temperatures and corrosive elements.

IPT-HD High-Voltage Connectors – Exhibits a modern shielding design that protects contact points from humid environments as well as dirt and extreme vibrations.

HVP800 cable assembly – Has a 16-50mm² discrete shielded wire, 360° shielding from wire to device and operating temperature range of -40°C to 140°C.

TE Connectivity’s innovations in miniaturisation and material science help mitigate the risks associated with high-density electronic packaging. By utilising advanced materials and engineering practices, TE Connectivity’s solutions ensure that EV components can operate safely and efficiently, even in the most compact and challenging environments.

Ensure the durability of your EV components with Dalroad

The trend towards miniaturisation in EV design represents both a challenge and an opportunity. Whilst it involves overcoming significant hurdles such as increased temperature and corrosion, it also drives the development of innovative solutions that enhance the performance and reliability of electric vehicles.

High-performance components, such as those offered by TE Connectivity, play a crucial role in this process, ensuring that EVs can meet the demands of modern drivers and the environmental challenges of the future.

At Dalroad, we provide a wide range of components designed to enhance the resilience and lifespan of EVs. Our team of specialists is on hand to assist you in finding the perfect components for your design, taking all factors into account. To find out more about our catalogue of components and get support in choosing the right ones for your design, contact a member of our team today.

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