The Road to Reliability: Why EV Electronics Matter More Than Ever

Estimated reading time: 2 minutes

Editor's note: This article is the first in a series meant to bring attention to the reliability challenges facing EV electronics components and systems. The articles are based on a comprehensive technical analysis being assembled by the Global Electronics Association.

The global transition to e-Mobility is redefining the design and reliability expectations of automotive electronics. Unlike their internal combustion engine (ICE) counterparts, EVs operate under "always-on" conditions and are subject to higher voltages, higher currents, and elevated thermal loads. These systems also incorporate exponentially more sensors, control units, and advanced power electronics, often tightly packed in thermally constrained spaces.

The proliferation of electronics is driven not only by electrification but also by customer demand for features like over-the-air (OTA) updates, connectivity, autonomous driving capabilities, and enhanced safety. While these features increase functionality, they also introduce new vectors for failure, especially when software and hardware development are not properly synchronized

In a survey by Molex and Mouser, 67% of industry respondents indicated that software development is prioritized over hardware, underscoring a growing imbalance that could compromise long-term reliability.

Additionally, new entrants to the automotive electronics supply chain may not be well-versed in high-reliability design and manufacturing practices for harsh environments. Compounding this challenge is a regulatory landscape still under development, with evolving requirements and a lack of consistent standards. This uncertainty has led to communication breakdowns between OEMs, Tier 1s, and EMS providers, making alignment on reliability targets elusive.

Defining the Scope of e-Mobility

e-Mobility spans far beyond passenger cars. It encompasses electric buses, trucks, motorcycles, off-road machinery, construction equipment, and even electric aircraft. While this series focuses primarily on automotive applications and their charging infrastructure, lessons from adjacent sectors are valuable.

For instance, according to KPMG, two- and three-wheel vehicles in Asia are seeing faster electrification adoption than passenger cars, bringing with them rapid innovation in battery thermal management². Similarly, fuel cell buses are pioneering hybrid thermal systems by integrating waste‑heat recovery and combined heating and cooling for batteries and cabins that could eventually inform thermal architectures in future passenger EVs³. Monitoring trends in these faster-moving sectors can provide valuable insights and potential technology transfers. The global EV market experienced over 35% annual growth between 2019 and 2023. Yet growth has recently plateaued in regions like Europe and the U.S. due to reduced government incentives, infrastructure inadequacies, and price pressures. The upside of this pause is a window of opportunity, an inflection point, to address foundational reliability issues before the next wave of accelerated growth.

To read the entire article, which originally appeared in the September 2025 edition of SMT007 Magazine, click here.