Q&A: miniaturisation in vehicle design

This transformative trend supports a wide range of innovations, from compact yet robust safety systems to high-speed connectivity solutions essential for connected mobility and advanced driver assist systems (ADAS).

Carrieanne Piccard, Vice President and General Manager of Transportation Solutions at Molex, shares insights into the challenges and opportunities of miniaturisation. She highlights how reducing the size of components impacts manufacturing, performance in extreme conditions, and the integration of cutting-edge technologies. By leveraging advances such as 48V architectures and multifunction connectors, the automotive industry continues to push boundaries, meeting the growing demands for efficiency and enhanced functionality.

How has miniaturisation impacted the overall design and functionality of modern vehicles?

Miniaturisation in vehicle design is primarily driven by demand for the integration of more features without increasing vehicle size.While the overall dimensions of vehicles remain consistent, the reduction in connector sizes enables the inclusion of advanced features such as large flat panel displays, for one example. This shift allows automakers to optimise space and improve functionality, ensuring that connectors remain robust enough to handle the shock, vibration, and temperature extremes typical of a vehicle's lifecycle. This miniaturisation supports the integration of additional features while maintaining or enhancing vehicle performance and reliability.

What are the main challenges associated with miniaturising vehicle components, particularly in terms of manufacturing and integration?

Traditionally, when making components more rugged, the orthodox approach would be to increase bulk and weight to provide added protection. However, the use of lighter and thinner materials, while also packing in more functionality, creates design challenges. New components must equal or outperform previous designs in performance, reliability, functionality, safety and efficiency, while also continuing to meet the same rigorous standards for temperature extremes, shock, vibration, and sealing.

As demand for miniaturised components soars, manufacturers must utilise advanced production techniques to achieve the smallest possible footprint without compromising on performance and functionality.

This demand is not exclusive to the automotive industry; it spans across multiple sectors. Optimising the design of connection systems enables the use of smaller wires while still achieving the required mechanical strength and electrical properties for reliable signal and power transmission.

How does miniaturisation affect the performance and reliability of vehicle systems, especially in extreme conditions?

While EVs generally experience less vibration and engine heat, miniaturised components still need to perform reliably in harsh environments, including off-road and in extreme weather. As systems become smaller, particularly with delicate electronic components, special consideration must be taken to ensure robustness and guarantee performance in diverse conditions. Connection systems must be designed to meet the same rigorous standards as traditional connectors to maintain vehicle performance, ensuring that all current-carrying connections remain secure.

How does miniaturisation impact vehicle safety systems, and what measures are taken to ensure these systems remain robust?

For any technical advances made in automotive, safety must always be a priority. Miniaturisation has enabled the development of smaller yet equally robust vehicle safety systems, and the emergence of connectors that are both rugged and small allows for the integration of additional safety features, such as side curtain airbags and external airbags, without compromising performance.This advancement ensures that safety standards continue to be met or exceeded.

In what ways has miniaturisation influenced the development and integration of connected mobility solutions?

Miniaturisation has significantly advanced connected mobility solutions by enabling seamless integration of high-speed data transfer interfaces like USB Type-C and Ethernet within vehicles. These advancements enhance the user experience, and improve functionality, allowing end users to do more with their vehicle. The reduced size of connectors facilitates the integration of these technologies without adding bulk, providing the necessary connectivity for features like advanced camera systems and infotainment solutions.

What technological advancements have enabled the recent strides in miniaturisation within vehicle design?

There has been a shift to 48V architectures, enabling smaller connectors and wires while maintaining power output, thus reducing weight. Additionally, the use of high-performance polymers and multifunction connectors is crucial for achieving compact design while ensuring durability. For example, multi-function connectors such as Molex’s Mx-DaSH integrate power, signal, and locking mechanisms into one compact unit. This reduces weight, size and cost requirements without compromising on functionality, allowing designers to achieve greater functionality within a smaller footprint.

Can you share specific examples of how Molex has contributed to the miniaturisation efforts in the automotive industry?

Molex has made significant strides in miniaturisation for automotive applications through several innovative solutions. To combat ingress with UL-approved IP68-rated seals, Molex’s Squba connectors protect against dust and prolonged submersion in water. Protective caps are also used to safeguard these seals during handling and assembly.

The demand for more electronics in limited spaces has driven Molex to develop Mini50 sealed and unsealed wire-to-board receptacles. These allow manufacturers to package circuits more compactly, reducing weight and costs. The Mini50 systems are particularly suited for infotainment, lighting, and HVAC applications due to their reliable performance in constrained environments.

As well as end users, installers and manufacturers must also be considered. Assembly errors put connectivity reliability at risk, and this creates additional challenges as systems become smaller and more complex. Molex’s stAK50h connection system offers unsealed hybrid headers to deliver both signal and Ethernet connectivity within a small footprint, while its stackable design streamlines installation and eliminates mis-mating without the need for specialist tools.

What future innovations in miniaturisation do you foresee having a significant impact on the automotive industry?

The future of miniaturisation in the automotive industry is closely tied to the increasing demand for advanced driver assist systems (ADAS) and autonomous technologies. These systems require a vast number of sensors and electronic components to enhance vehicle safety and functionality, prompting a need for miniaturised connectors and components that Molex is well suited to support.

Current advancements in connector technology already support the integration of sensors across a wide range of applications. This includes not only traditional automotive vehicles but also extends to non-automotive sectors such as public transit, agriculture, and construction. These industries benefit from the same trends in miniaturisation, which allow for the deployment of complex systems in more compact and efficient forms.

Overall, the industry's focus on miniaturisation is preparing it to address the evolving needs of vehicle manufacturers, enabling the widespread adoption of innovative technologies that will shape the future of transportation across various sectors.

How is Molex preparing to address the demands of future vehicle designs that will require even more advanced miniaturisation?

Molex is proactively addressing future demands by ensuring all new designs meet global standards such as USCAR, LV214, and GMW 3191. The Molex Global Reliability Lab rigorously tests products under harsh conditions to guarantee performance. Additionally, the use of 3D printing and additive manufacturing accelerates prototype development, allowing Molex to swiftly adapt to and meet the evolving needs of the automotive industry. This ensures that Molex is well-prepared to meet future demands for miniaturised solutions.