As the EV landscape continues to evolve, the latest innovations in electric mobility from TE Connectivity show how smarter connector systems shape how vehicles charge, drive, and stay safe under rising voltage demands.
At the 2025 Battery Show, Munro’s coverage highlighted TE’s full-spectrum approach — from 48 V auxiliaries to 800 V traction drives — as well as the tools used to assemble them. In particular, the walkthrough emphasized how each interface contributes to higher efficiency and manufacturing consistency across voltage classes.
For both engineers and investors, this means clearer insight into how lean integration, part reduction, and process capability now converge to shape the next generation of EV platforms.
From 48 V auxiliaries to full e-drive
TE explicitly positions itself as a one-stop supplier for all major connection needs — from small auxiliary systems to main traction drives and in-vehicle data links. Using fewer suppliers makes it easier to design parts that fit together, test them for quality, and keep costs under control.
As a result, TE’s 48 V suite, developed with an early segment leader, delivers power and mass savings that scale vehicle-wide. Education supports adoption; OEM engineers must understand both technical fit and integration workflows to unlock those benefits.
NACS inlets, materials flexibility, and regional compliance
At the charge port, TE supports stranded copper, stranded aluminum, and bus-bar feed paths. This flexibility lets OEMs balance conductivity, mass, and cost across trims. TE also stressed vertical integration and USMCA compliance — a protection against tariff exposure, IRA sourcing rules, and logistics delays. For manufacturers in North America, local copper sourcing and easier testing loops reduce friction and speed launches.
Touch-safe power paths and service protection
Inside the pack, TE’s patented VCON+ system blocks accidental contact with energized metal. Touch-safe architecture protects assemblers and service teams while enabling dense layouts at higher voltage. TE’s AC-stack connectors, used in several 0–60 champions, transfer power and shed heat efficiently. These connectors dictate performance and reliability as much as any motor or inverter does.
TE Connectivity electric mobility focus: pack-top “X-in-1”
Most next-gen packs integrate switching, bus bars, and control into a penthouse “X-in-1” box. TE supplies both high- and low-voltage interfaces inside this enclosure, simplifying sealing, reducing penetrations, and shortening HV runs. The result is lower copper mass, better EMC control, and fewer assembly steps. Lean design starts here — in standardized seals and shared hardware that cut leaks and rework.
Bus bars vs. cables: design trade-offs
TE’s electric mobility work balances strength with flexibility. Bus bars give the structure more stiffness, make parts easier to repeat in production, and help spread heat evenly. Cables, on the other hand, bend around tight spaces and move safely through areas designed to absorb impact. TE’s bolted connector design, first used in China and now adapted for North America, shows how sharing proven designs across regions speeds up learning and reduces risk. Both methods focus on keeping enough distance between live parts, preventing electrical arcing, and allowing safe disconnection while current is flowing.
Manufacturing gear as a design variable
Connector reliability depends on repeatable preparation and crimping. Accordingly, TE builds the assembly tools that ensure it:
- HVCP2 cable prep system. Strips insulation to 0.125 mm precision, protects conductors, and records process data for traceability. Changeovers take minutes, enabling flexible, low-defect production.
- T-series bench terminators. Evolve from TE’s AMP K-press lineage with modern SPC, on-press monitoring, and modular applicators for low-voltage crimps.
Treating tooling as part of DFMA ensures joint integrity, reduces rework, and keeps warranty costs predictable. For this reason, designers must include assembly equipment and operator training in their costed BOMs and PPAPs.
Heavy-duty readiness: megawatt charging
TE Connectivity electric mobility work also extends to Class 8 trucks. Megawatt-scale connectors multiply thermal and mechanical challenges. Every milliohm of contact resistance matters. Consequently, robust bolted joints, optimized cooling, and fast service features define the hardware. Coordinating connector design with depot infrastructure and cable management minimizes field risk during fleet ramp-up.
Cost and lean design levers
From TE’s portfolio, engineers can extract practical takeaways:
- Standardize interfaces early. Fix inlet and pack interfaces before customization. This freezes geometry for EMC and safety while freeing midpath optimization.
- Leverage regional content. USMCA compliance and local copper trim risk and inventory exposure. Model savings in landed-cost reviews.
- Design for safety. Use touch-safe systems like VCON+ and keyed housings to prevent mis-mates.
- Integrate equipment into DFMA. Account for prep tools, monitors, and seal compression audits in PPAP validation.
- Plan X-in-1 consolidation. Combine HV switching and LV comms early to reduce penetrations and shorten cable length.
- Adopt global variants fast. Proven bolted connectors from China adapt quickly under North American compliance — accelerating safe volume production.
Each lever supports lean design by aligning process control with hardware reliability.
What to watch next
- Material optimization by trim. Expect copper in high-power variants and aluminum in cost-driven ones; verify thermal performance before freeze.
- Faster service design. More touch-safe and keyed joints to shorten repair times.
- Process analytics. Expanded use of crimp monitors and prep data to connect plant quality with warranty tracking.
Explore More With Munro
Whether you’re benchmarking your first EV platform or looking to improve a mature design, there’s always more to uncover in the world of next-gen mobility. Visit Munro & Associates or check out Munro Live‘s library of informative videos today. From there, you can trace how similar insights simplify architecture, trim copper mass, and strengthen validation across your own programs.
Additionally, for teams seeking deeper teardown analysis, cost breakdowns, and lean design reviews, Munro offers a clear route from prototype learning to dependable volume production.