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US Automotive Secondary Wiring Harness Market

ID: MRFR/AT/11618-HCR
100 Pages
Garvit Vyas
October 2025

US Automotive Secondary Wiring Harness Market Research Report By Application (Cabin, Door Harness, Engine, Electronic Parking Brakes, Airbag Harness, Electronic Gear Shift System) and By Vehicle Type (ICE, EV) - Forecast to 2035

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US Automotive Secondary Wiring Harness Market Summary

As per analysis, the US Automotive Secondary Wiring Harness Market is projected to grow from USD 0.896 Billion in 2025 to USD 1.67 Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 6.33% during the forecast period (2025 - 2035).

Key Market Trends & Highlights

The US Automotive Secondary Wiring Harness Market is poised for growth driven by technological advancements and evolving consumer preferences.

  • The integration of advanced technologies is reshaping the automotive secondary wiring harness landscape.
  • Body wiring remains the largest segment, while engine wiring is experiencing the fastest growth due to increasing complexity in vehicle designs.
  • Passenger vehicles dominate the market, yet electric vehicles are emerging as the fastest-growing segment amid rising environmental concerns.
  • Key market drivers include the growing electric vehicle adoption and the rising demand for vehicle safety features.

Market Size & Forecast

2024 Market Size 0.848 (USD Billion)
2035 Market Size 1.67 (USD Billion)
CAGR (2025 - 2035) 6.33%

Major Players

Delphi Technologies (US), Lear Corporation (US), Aptiv PLC (US), Yazaki Corporation (JP), Sumitomo Electric Industries (JP), Marelli Holdings (JP), Kostal Group (DE), TE Connectivity (CH), Furukawa Electric Co. (JP)

US Automotive Secondary Wiring Harness Market Trends

The US Automotive Secondary Wiring Harness Market is currently experiencing a notable evolution, driven by advancements in automotive technology and increasing consumer demand for enhanced vehicle performance. Secondary wiring harnesses, which serve as essential components in connecting various electrical systems within vehicles, are becoming increasingly sophisticated. This trend is largely influenced by the growing integration of electronic features in automobiles, such as advanced driver-assistance systems and infotainment technologies. As vehicles become more reliant on electrical systems, the importance of reliable and efficient wiring harnesses cannot be overstated. Furthermore, the push towards electric vehicles is likely to reshape the market landscape, as these vehicles require specialized wiring solutions to accommodate their unique power and data transmission needs. In addition to technological advancements, regulatory frameworks in the US are also impacting the Automotive Secondary Wiring Harness Market. Stricter safety and environmental regulations are prompting manufacturers to innovate and improve the quality of wiring harnesses. This regulatory environment encourages the adoption of materials that enhance durability and reduce weight, thereby contributing to overall vehicle efficiency. As the market continues to evolve, it appears that collaboration between automotive manufacturers and wiring harness suppliers will be crucial in addressing the challenges posed by new technologies and regulations. The future of the US Automotive Secondary Wiring Harness Market seems promising, with opportunities for growth and innovation on the horizon.

Integration of Advanced Technologies

The US Automotive Secondary Wiring Harness Market is witnessing a trend towards the integration of advanced technologies. As vehicles increasingly incorporate sophisticated electronic systems, the demand for wiring harnesses that can support these innovations is rising. This includes features such as connectivity, automation, and enhanced safety systems, which require more complex wiring solutions.

Focus on Lightweight Materials

There is a growing emphasis on the use of lightweight materials in the production of secondary wiring harnesses. This trend is driven by the automotive industry's need to improve fuel efficiency and reduce emissions. Manufacturers are exploring materials that not only decrease weight but also maintain durability and performance under various conditions.

Regulatory Compliance and Safety Standards

The regulatory landscape in the US is becoming more stringent, particularly concerning safety and environmental standards. This trend is influencing the design and manufacturing processes of secondary wiring harnesses. Companies are increasingly prioritizing compliance with these regulations, which is likely to lead to innovations in materials and manufacturing techniques.

US Automotive Secondary Wiring Harness Market Drivers

Growing Electric Vehicle Adoption

The US Automotive Secondary Wiring Harness Market is experiencing a notable shift due to the increasing adoption of electric vehicles (EVs). As consumers and manufacturers alike prioritize sustainability, the demand for EVs is projected to rise significantly. According to recent data, the EV market in the US is expected to grow at a compound annual growth rate (CAGR) of over 20% through 2026. This surge necessitates advanced wiring harnesses that can support the complex electrical systems in EVs, including battery management and power distribution. Consequently, manufacturers are investing in innovative wiring solutions to meet the evolving needs of the automotive sector, thereby driving growth in the secondary wiring harness market.

Increased Focus on Fuel Efficiency

The US Automotive Secondary Wiring Harness Market is also driven by an increased focus on fuel efficiency among consumers and manufacturers. As fuel prices fluctuate and environmental concerns grow, there is a strong push towards developing lighter and more efficient vehicles. Secondary wiring harnesses play a crucial role in achieving this goal, as they can be designed to be lighter without compromising functionality. The market is witnessing a trend towards the use of lightweight materials in wiring harness production, which can contribute to overall vehicle weight reduction. This shift is expected to enhance fuel efficiency, thereby driving demand for innovative wiring solutions in the automotive sector.

Rising Demand for Vehicle Safety Features

The US Automotive Secondary Wiring Harness Market is significantly influenced by the rising demand for enhanced vehicle safety features. Consumers are increasingly prioritizing safety, leading to the incorporation of advanced driver-assistance systems (ADAS) in new vehicle models. These systems require complex wiring harnesses to connect various sensors, cameras, and control units. As a result, the market for secondary wiring harnesses is expected to expand, with estimates suggesting a growth rate of approximately 5% annually through 2026. Manufacturers are thus focusing on developing wiring solutions that not only meet safety standards but also enhance the overall performance of these advanced systems.

Technological Advancements in Automotive Design

The US Automotive Secondary Wiring Harness Market is being propelled by rapid technological advancements in automotive design. Innovations such as smart wiring harnesses, which integrate sensors and communication technologies, are becoming increasingly prevalent. These advancements enable vehicles to achieve higher levels of automation and connectivity, aligning with consumer expectations for enhanced functionality. The integration of these technologies is expected to increase the complexity of wiring systems, thereby driving demand for secondary wiring harnesses. As manufacturers adapt to these changes, the market is likely to witness a shift towards more sophisticated wiring solutions that can accommodate the growing number of electronic components in modern vehicles.

Regulatory Pressures and Compliance Requirements

The US Automotive Secondary Wiring Harness Market is subject to stringent regulatory pressures and compliance requirements aimed at ensuring vehicle safety and environmental sustainability. Government regulations mandate that automotive manufacturers adhere to specific standards regarding wiring systems, including fire resistance and durability. These regulations compel manufacturers to invest in high-quality secondary wiring harnesses that meet or exceed compliance standards. As the regulatory landscape continues to evolve, the demand for advanced wiring solutions that can fulfill these requirements is likely to increase. This trend not only drives innovation within the market but also ensures that manufacturers remain competitive in a rapidly changing automotive environment.

Market Segment Insights

By Application: Body Wiring (Largest) vs. Engine Wiring (Fastest-Growing)

In the US Automotive Secondary Wiring Harness Market, the body wiring segment holds the largest share, owing to its crucial role in connecting essential vehicle systems. This segment facilitates various functionalities such as window operations, seat adjustments, and infotainment systems. Following closely are the engine and chassis wiring segments, both of which play pivotal roles in power distribution and vehicle performance. The market also witnesses noteworthy contributions from lighting and sensor wiring, though they trail in terms of overall share.

Body Wiring (Dominant) vs. Engine Wiring (Emerging)

The body wiring segment is characterized by its extensive use in a multitude of automotive applications, making it a dominant force in the market. It integrates multiple functionalities, ensuring seamless communication between various systems within the vehicle, which is crucial for safety and comfort. In contrast, the engine wiring segment, marked as emerging, is rapidly gaining traction due to the increasing complexity of engine management systems and the shift towards electric and hybrid vehicles. This demand is driven by technological advancements aimed at enhancing vehicle efficiency and performance, indicating a promising growth trajectory for engine wiring in the coming years.

By End Use: Passenger Vehicles (Largest) vs. Electric Vehicles (Fastest-Growing)

In the US Automotive Secondary Wiring Harness Market, the distribution of market share among the various end-use segments reflects a significant preference for passenger vehicles, which dominate the market. This segment benefits from a robust demand driven by rising consumer preference for personal transportation and the ongoing expansion of the automobile industry. While commercial vehicles form a respectable part of the market, electric and hybrid vehicles are gaining traction as they align with the trends towards sustainable transportation.

Passenger Vehicles (Dominant) vs. Electric Vehicles (Emerging)

Passenger vehicles remain the dominant segment within the US Automotive Secondary Wiring Harness Market due to their widespread use and reliance on advanced electrical systems for safety and convenience features. On the other hand, electric vehicles represent an emerging segment that is rapidly gaining ground. Their market position is influenced by increasing consumer awareness of environmental issues and advancements in battery technology, which enhance their viability and appeal. As automakers pivot towards electrification, the demand for specialized wiring harness solutions for electric vehicles is set to increase significantly, highlighting a transformative shift in consumer preferences.

By Material Type: Copper (Largest) vs. Aluminum (Fastest-Growing)

In the US Automotive Secondary Wiring Harness Market, the material type segment is notably dominated by copper, which is recognized for its excellent conductivity and durability. Copper's superior properties make it the preferred choice among automakers, leading to its significant market share. In contrast, aluminum, while still a competitive player, is gaining traction due to its lightweight properties, offering potential for improved fuel efficiency in vehicles. Market distribution shows that as manufacturers seek to innovate and optimize vehicle designs, the balance between copper and aluminum is evolving.

Material: Copper (Dominant) vs. Aluminum (Emerging)

Copper remains the dominant material in the US Automotive Secondary Wiring Harness Market due to its unmatched conductivity, reliability, and longstanding usage in electrical systems. Its ability to handle high currents without significant loss makes it indispensable for premium automotive applications. On the other hand, aluminum is emerging as a significant alternative, especially as automakers push for lighter materials to enhance vehicle performance and fuel efficiency. The shift towards aluminum is driven by technological advancements, yet challenges such as conductivity and corrosion resistance remain critical considerations in its broader adoption.

By Connector Type: Sealed Connectors (Largest) vs. Modular Connectors (Fastest-Growing)

In the US Automotive Secondary Wiring Harness Market, the connector type segment is delineated among sealed, unsealed, modular, and custom connectors. Sealed connectors command the largest market share due to their reliability and durability, offering protection against environmental factors. Unsealed connectors, while less durable, cater to cost-sensitive applications where sealing is not a critical concern. The focus on modular connectors is rapidly increasing, given their flexibility and ease of assembly, appealing to manufacturers looking to streamline production processes.

Sealed Connectors (Dominant) vs. Modular Connectors (Emerging)

Sealed connectors hold a dominant position in the US automotive market, recognized for their exemplary performance in harsh conditions. They provide an exceptional level of protection against moisture, dirt, and other contaminants, ensuring long-term reliability and reduced maintenance. Modular connectors, on the other hand, are emerging prominently due to their adaptability and ease of integration into various automotive applications. As manufacturers aim to enhance assembly efficiency, the demand for modular connectors is steadily rising, leading to innovative designs that combine functionality with user-friendliness.

By Wire Gauge: Low Gauge (Largest) vs. High Gauge (Fastest-Growing)

In the US Automotive Secondary Wiring Harness Market, the wire gauge segment is driven primarily by low, medium, and high gauge options. Low gauge wires are the largest segment, mainly due to their utilization in high-current applications, which are critical in modern vehicles for power distribution. Meanwhile, medium gauge wires maintain a balanced share across different vehicle types, serving moderate current demands effectively. High gauge wires, although smaller in overall market share, are rapidly gaining attention as vehicles become lighter and more efficient, necessitating a shift towards these thinner, lighter options.

Wire Gauge: Low Gauge (Dominant) vs. High Gauge (Emerging)

Low gauge wires are dominant in the US Automotive Secondary Wiring Harness Market, characterized by their heavy-duty capabilities and widespread application in essential vehicle systems like engines and power distribution, making them a crucial component in ensuring safety and efficiency. In contrast, high gauge wires are emerging as a significant segment, favored for their lightweight and flexible nature, which is increasingly preferred in contemporary automotive designs focused on weight reduction and enhanced fuel efficiency. This shift reflects manufacturers' adaptability to evolving industry standards and consumer expectations, positioning high gauge wires as a growing choice for innovative automotive electrical systems.

Get more detailed insights about US Automotive Secondary Wiring Harness Market

Key Players and Competitive Insights

The Automotive Secondary Wiring Harness Market is characterized by a competitive landscape that is increasingly shaped by innovation, strategic partnerships, and a focus on sustainability. Key players such as Delphi Technologies (US), Lear Corporation (US), and Aptiv PLC (US) are actively pursuing strategies that enhance their market positioning. Delphi Technologies (US) emphasizes technological advancements in wiring solutions, aiming to improve vehicle performance and safety. Meanwhile, Lear Corporation (US) focuses on expanding its product portfolio through strategic acquisitions and partnerships, thereby enhancing its capabilities in the automotive sector. Aptiv PLC (US) is leveraging digital transformation to optimize its operations and improve customer engagement, which collectively influences the competitive dynamics of the market.

The business tactics employed by these companies include localizing manufacturing and optimizing supply chains to enhance efficiency and reduce costs. The market structure appears moderately fragmented, with several key players exerting considerable influence. This fragmentation allows for a diverse range of offerings, but also intensifies competition as companies strive to differentiate themselves through innovation and service quality.

In November 2025, Delphi Technologies (US) announced a partnership with a leading electric vehicle manufacturer to develop advanced wiring harness solutions tailored for electric vehicles. This collaboration is strategically significant as it positions Delphi at the forefront of the growing electric vehicle market, potentially increasing its market share and reinforcing its commitment to sustainability.

In December 2025, Lear Corporation (US) unveiled a new manufacturing facility in the Midwest, aimed at enhancing its production capabilities for secondary wiring harnesses. This move is indicative of Lear's strategy to localize production, thereby reducing lead times and improving supply chain resilience. The facility is expected to create numerous jobs and contribute to the local economy, while also aligning with the company's sustainability goals by minimizing transportation emissions.

In January 2026, Aptiv PLC (US) launched a new digital platform designed to streamline the design and manufacturing processes of wiring harnesses. This platform integrates AI and machine learning technologies, which could significantly enhance operational efficiency and reduce time-to-market for new products. The introduction of this platform reflects Aptiv's commitment to innovation and its proactive approach to meeting the evolving demands of the automotive industry.

As of January 2026, the competitive trends in the Automotive Secondary Wiring Harness Market are increasingly defined by digitalization, sustainability, and the integration of AI technologies. Strategic alliances among key players are shaping the landscape, fostering innovation and enhancing product offerings. The shift from price-based competition to a focus on technological advancement and supply chain reliability is evident, suggesting that companies will need to prioritize innovation and sustainability to maintain a competitive edge in the future.

Key Companies in the US Automotive Secondary Wiring Harness Market include

Industry Developments

In recent developments within the US Automotive Secondary Wiring Harness Market, significant growth has been observed, primarily driven by the rising demand for electric vehicles and advancements in automotive technology. Several key players, including Bosch, Yazaki Corporation, Delphi Technologies, and Aptiv, are investing heavily in Research and Development to enhance the durability and efficiency of wiring harness systems. In September 2023, Delphi Technologies announced a strategic partnership with General Motors to develop innovative wiring solutions aimed at improving electric vehicle performance. 

Furthermore, Lear Corporation has been expanding its manufacturing capabilities, responding to the surge in electric vehicle production. Notably, in October 2022, Ford Motor completed the acquisition of a small tech firm focused on automotive wiring technology to bolster its expertise in this area. Moreover, TE Connectivity has been actively increasing its market footprint through collaborations with multiple automotive manufacturers in the U.S. Market valuation is positively impacted by these efforts, reflecting a growing emphasis on integrating advanced technologies in automotive manufacturing.

Over the last few years, the sector has also faced challenges, including supply chain disruptions, which have compelled companies to rethink their procurement and production strategies.

Future Outlook

US Automotive Secondary Wiring Harness Market Future Outlook

The US Automotive Secondary Wiring Harness Market is projected to grow at a 6.33% CAGR from 2025 to 2035, driven by advancements in electric vehicles, increased automation, and enhanced connectivity features.

New opportunities lie in:

  • Development of lightweight, high-performance materials for wiring harnesses.
  • Integration of smart technology for real-time diagnostics and monitoring.
  • Expansion into aftermarket services for customized wiring solutions.

By 2035, the market is expected to be robust, reflecting substantial growth and innovation.

Market Segmentation

US Automotive Secondary Wiring Harness Market End Use Outlook

  • Passenger Vehicles
  • Commercial Vehicles
  • Electric Vehicles
  • Hybrid Vehicles

US Automotive Secondary Wiring Harness Market Wire Gauge Outlook

  • Low Gauge
  • Medium Gauge
  • High Gauge

US Automotive Secondary Wiring Harness Market Application Outlook

  • Body Wiring
  • Chassis Wiring
  • Engine Wiring
  • Lighting Wiring
  • Sensor Wiring

US Automotive Secondary Wiring Harness Market Material Type Outlook

  • Copper
  • Aluminum
  • Plastic
  • Rubber

US Automotive Secondary Wiring Harness Market Connector Type Outlook

  • Sealed Connectors
  • Unsealed Connectors
  • Modular Connectors
  • Custom Connectors

Report Scope

MARKET SIZE 20240.848(USD Billion)
MARKET SIZE 20250.896(USD Billion)
MARKET SIZE 20351.67(USD Billion)
COMPOUND ANNUAL GROWTH RATE (CAGR)6.33% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Billion
Key Companies ProfiledDelphi Technologies (US), Lear Corporation (US), Aptiv PLC (US), Yazaki Corporation (JP), Sumitomo Electric Industries (JP), Marelli Holdings (JP), Kostal Group (DE), TE Connectivity (CH), Furukawa Electric Co. (JP)
Segments CoveredApplication, End Use, Material Type, Connector Type, Wire Gauge
Key Market OpportunitiesIntegration of advanced materials and smart technologies in the US Automotive Secondary Wiring Harness Market.
Key Market DynamicsRising demand for electric vehicles drives innovation in the US Automotive Secondary Wiring Harness Market.
Countries CoveredUS
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FAQs

What is the projected market valuation of the US Automotive Secondary Wiring Harness Market by 2035?

<p>The market is projected to reach a valuation of 1.67 USD Billion by 2035.</p>

What was the market valuation of the US Automotive Secondary Wiring Harness Market in 2024?

<p>In 2024, the market valuation stood at 0.848 USD Billion.</p>

What is the expected CAGR for the US Automotive Secondary Wiring Harness Market during the forecast period 2025 - 2035?

<p>The expected CAGR for the market during this period is 6.33%.</p>

Which companies are considered key players in the US Automotive Secondary Wiring Harness Market?

<p>Key players include Delphi Technologies, Lear Corporation, Aptiv PLC, Yazaki Corporation, and Sumitomo Electric Industries.</p>

What are the primary applications of automotive secondary wiring harnesses?

<p>The primary applications include Body Wiring, Chassis Wiring, Engine Wiring, Lighting Wiring, and Sensor Wiring.</p>

How does the market for passenger vehicles compare to commercial vehicles in terms of wiring harness demand?

<p>The demand for wiring harnesses in passenger vehicles was 0.425 USD Billion, compared to 0.215 USD Billion for commercial vehicles.</p>

What materials are predominantly used in the manufacturing of automotive secondary wiring harnesses?

<p>The predominant materials include Copper, Aluminum, Plastic, and Rubber.</p>

What types of connectors are utilized in the automotive secondary wiring harness market?

<p>The market utilizes Sealed Connectors, Unsealed Connectors, Modular Connectors, and Custom Connectors.</p>

What wire gauge categories are present in the automotive secondary wiring harness market?

<p>The wire gauge categories include Low Gauge, Medium Gauge, and High Gauge.</p>

What was the valuation of the engine wiring segment in the US Automotive Secondary Wiring Harness Market in 2024?

<p>The engine wiring segment was valued at 0.2 USD Billion in 2024.</p>

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