Steer-by-Wire System Benefits and Safety Insights from ZF

As electric vehicles continue to redefine what’s possible in automotive design, steer-by-wire technology is emerging as a game-changer. In a recent in-depth demonstration hosted by ZF and Munro & Associates, engineers explored the full capabilities of steer-by-wire systems—highlighting safety, flexibility, and performance in both rear-wheel steering and fully decoupled steering architecture. These systems offer enhanced driver control, open up design possibilities, and improve safety, especially for EV platforms.

What Is Steer-by-Wire?

Steer-by-wire eliminates the traditional mechanical connection between the steering wheel and the front wheels. Instead, it uses electronic sensors, actuators, and control units to simulate the feel of conventional steering while allowing unprecedented flexibility and customization. As ZF’s Chris Mantzios, a steering feel expert, explained, steer-by-wire includes dual actuators: one on the front wheels and another on the hand wheel. These communicate via software modules to create a seamless, customizable steering experience.

This architecture allows OEMs to tailor the steering feel dynamically—something mechanical systems can’t replicate. With steer-by-wire, vehicle platforms can switch effortlessly between “comfort” and “sport” modes, change ratios at different speeds, or even enable advanced driver-assistance systems (ADAS) and autonomous functionality.

Rear-Wheel Steering in Action

The demonstration began with real-world parking maneuvers using a long-wheelbase F-150 Lightning development vehicle outfitted with ZF’s rear-wheel steering. When the system was active, parking the vehicle was smooth, fast, and precise. With the system turned off, the same maneuver became awkward and time-consuming. Even seasoned drivers struggled with alignment and positioning.

ZF’s Neb Stevanovich, Steering Portfolio Manager for North America, emphasized how four-wheel steering enhances both low-speed maneuverability (tight parking spots, U-turns) and high-speed stability (lane changes, evasive maneuvers). For large electric pickups and SUVs—where weight and wheelbase are substantial—rear-wheel steering is a major leap forward.

Demonstrating Steer-by-Wire in the VW ID.3

Next, Munro’s team explored steer-by-wire in a VW ID.3 equipped with ZF’s decoupled system. Armin, a lead chassis engineer at Munro, noted that the system transformed the vehicle’s feel. In “yoke mode,” which dramatically increases the steering ratio, the ID.3 responded like a nimble sports car—comparable to a Mazda Miata. With a push of a button, the system returned to comfort mode for everyday driving.

The key innovation here is variable C-factor (steering ratio), which dynamically changes based on speed and driver input. This fine-grained control allows for quicker lock-to-lock turns at low speeds while reducing twitchiness at highway speeds. All of this is managed via software, without changing mechanical components.

Software-Defined Steering: Benefits Beyond Feel

ZF’s system allows full software-defined customization. Engineers can tune steering feel for every model, trim, or even driver, without adding hardware complexity. As Mantzios described, feedback can be turned off, adjusted for center feel (hysteresis), or even enhanced with active return forces. This makes the driving experience both more adaptive and more intuitive.

Moreover, steer-by-wire supports significant weight savings. Traditional mechanical linkages, universal joints, and steering columns are eliminated. This not only saves several kilograms per vehicle but also increases crush space for crash safety—something ZF explicitly designed into its compact steering actuator.

Safety First: The Core of Steer-by-Wire Design

Throughout the demo, safety remained a dominant theme. Steer-by-wire is designed with ISO 26262 functional safety standards in mind. The system includes:

• Redundant Power: Dual power supplies prevent single-point failures.

• Redundant Communication: Dual CAN channels and fallback logic.

• Dual Sensors: Independent sensing of torque, angle, and vehicle dynamics.

• Fail-Operational Design: In the event of failure, the system provides limp-home capability using backup actuators or alternate wheel control.

Importantly, the decoupled nature of steer-by-wire eliminates dangerous wheel feedback during collisions or aggressive maneuvers. As Sandy Munro pointed out, there’s no steering column to whip back toward the driver—a crucial safety advantage in high-speed ADAS or autonomous contexts.

48V Compatibility and System Scalability

While the demo vehicle ran on a 12V system, ZF confirmed that its steer-by-wire platform is fully compatible with 48V architectures. The benefits are clear: higher efficiency, reduced motor sizes, and lower current demands. For larger EVs or premium applications, transitioning to 48V unlocks better thermal and power management.

ZF also highlighted the scalability of its solution—from compact cars to heavy-duty trucks. With a single compact actuator design that fits across models, OEMs can reduce tooling costs, eliminate left- vs. right-hand drive part duplication, and simplify global platform development.

A Game-Changer for EV Platforms

Steer-by-wire supports the vision of a true “skateboard” chassis, where a common platform can support multiple top hats—from sedans to pickups—without redesigning the steering system. That makes it a powerful enabler for modular EV architectures, flexible manufacturing, and cost-effective scaling.

From an efficiency standpoint, steer-by-wire and rear-wheel steering reduce tire scrub, improve range, and can even lower rolling resistance. That translates to reduced battery consumption, better wear-and-tear profiles, and a smoother, quieter ride.

The Road Ahead: Adoption Timelines

ZF anticipates wide rollout of steer-by-wire systems across all major regions (North America, Europe, Asia) by the end of 2025. While initial applications will appear in premium trims or niche performance vehicles, the technology’s value proposition—better safety, lower cost, greater flexibility—will drive adoption down-market in the coming years.

Rear-wheel steering, already launched in over 70 vehicle models across 19 OEMs, is expected to grow even faster, especially as vehicle sizes increase and autonomy features become standard.

Conclusion: Why Steer-by-Wire Matters

Steer-by-wire isn’t just a steering upgrade—it’s a reimagining of vehicle control. By decoupling physical components and embracing digital flexibility, ZF has created a system that enhances safety, improves handling, and reduces cost and complexity. Whether it’s tight parking in Detroit or sport-like cornering in an ID.3, the advantages are immediate and undeniable.

For OEMs, investors, and EV engineers, this is a pivotal moment. Steer-by-wire opens up the future of software-defined vehicles, modular design, and safer, more responsive driving.

Explore More With Munro

Subscribe to Munro Live and keep it on Munro & Associates for more teardowns and engineering analysis. Dive into our full library of reviews and breakdowns—and see what tomorrow’s vehicles are made of.