The Application and Trends of Eco-Friendly Materials in Wire Harnesses
2025-10-24 15:30— How Kehan Electronics Drives Sustainable Connections for the Future
? When Sustainability Becomes the Industry’s Core Value
Under the dual momentum of the EU Battery Regulation (2027) and China’s Dual Carbon Policy, the global wire harness industry is entering a new era of green transformation. The traditional PVC-based insulation systems are being rapidly replaced by renewable, bio-based, halogen-free, and recyclable materials.
For key components that connect electrical and energy systems—such as auto wiring harnesses—this is more than a material shift; it marks a revolution in sustainable manufacturing.
Founded in 2010, Xiamen Kehan Electronics Co., Ltd. is at the forefront of this transformation. With the mission “Innovative Connection · Sustainable Future,” Kehan Electronics is integrating eco-friendly materials into its Lightweight Wiring Harness and Advanced Materials Cable designs, creating sustainable solutions from the source of every connection.
? 1. Global Trend: The Rise of Eco-Friendly Materials in Wire Harness Manufacturing
Sustainability has become the driving force behind innovation in wire harness design. While PVC still dominates due to cost efficiency and flexibility, its chlorine-based composition releases harmful gases when burned—failing to meet stricter ROHS and REACH standards.
Emerging materials are redefining the new generation of wire harnesses:
Bio-Based Insulation Materials
Materials such as PLA (Polylactic Acid) and PA11 (Polyamide 11) are gradually replacing PVC.
For example, BASF’s Ultramid® Bio PA—made from castor oil—reduces carbon footprint by 60%.
Already adopted in the SAIC IM L7 EV for large-scale wire harness production.
Halogen-Free Flame-Retardant Sheathing
Incorporates mineral-based flame retardants like Mg(OH)₂ and Al(OH)₃ for safety and environmental protection.
Ensures low smoke and low toxicity in case of fire, essential for medical and automotive applications.
Closed-Loop Recycling Systems
Enables over 95% copper and aluminum recovery efficiency.
Reduces material waste and supports full lifecycle sustainability.
Through these advancements, the modern wire harness achieves lighter weight, higher safety, and improved recyclability—meeting the demands of automotive, medical, and energy industries worldwide.
? 2. Kehan Electronics’ Breakthrough: From Materials to Systems
As a specialized manufacturer of wire harness products, Kehan Electronics has built a fully integrated green manufacturing system—from raw material selection to product assembly and certification.
? 1. Material Innovation: High Performance Meets Sustainability
Strategic cooperation with leading suppliers of Advanced Materials Cable.
Development of halogen-free polyolefin and bio-based nylon composite sheathing.
Certified under UL and ISO 9001:2015, ensuring performance and environmental compliance.
? 2. Process Optimization: Lightweight & Automated Production
Advanced Lightweight Wiring Harness design reduces total vehicle harness weight by 10–15%.
Precision terminal crimping and automated assembly improve conductivity and consistency.
Smart testing systems guarantee compliance with REACH and international environmental standards.
? 3. Design Collaboration: Tailored Engineering Solutions
Kehan’s engineering team works closely with clients from concept to production:
Offers OEM and custom auto wiring harness design based on customer drawings.
Optimizes wire gauge, materials, and layout for cost efficiency and durability.
Solutions are widely used in automobiles, LED lighting, medical equipment, industrial machinery, and heating systems.
? 3. EU and China Policies: The Twin Engines of Green Manufacturing
? EU Battery Regulation (2027)
Mandates traceable carbon reduction certification for all wire harness materials.
Requires ≥95% material recyclability and bans halogenated flame retardants.
?? China’s Dual Carbon Policy
Promotes low-carbon manufacturing and green supply chains.
Encourages bio-based and degradable material innovation.
By aligning with both EU and Chinese sustainability frameworks, Kehan Electronics provides fully compliant auto wiring harness solutions for global automotive and electronics manufacturers.
⚙️ 4. Real-World Applications: Green Connections Across Industries
Kehan’s innovation in wire harness has transformed product performance across multiple industries through advanced material engineering:
? New Energy Vehicles (EV/HEV)
High-temperature lightweight harnesses improve range and efficiency.
PA11 sheathing withstands up to 200°C.
Integral part of next-gen auto wiring harness systems for EVs.
? LED and Electronics
Halogen-free cables reduce emissions and enhance safety.
Long-term stability and flexibility for compact designs.
? Medical Equipment
Biocompatible materials ensure safety and hygiene.
Waterproof, anti-bacterial, and interference-proof configurations.
? Industrial Automation and Machinery
Flexible multi-core harnesses simplify installation and maintenance.
Extends service life by over 30%.
? 5. FAQ: Everything You Want to Know About Green Wire Harnesses
Q1: Are eco-friendly wire harnesses much more expensive than traditional ones?
A1: Material costs are initially 10–15% higher, but with mass production and recycling, overall lifecycle costs are comparable.
Q2: How durable are biodegradable materials?
A2: Modern PLA and PA11 materials have heat resistance above 120°C, meeting automotive-grade requirements.
Q3: Does Kehan Electronics support custom eco-friendly wire harnesses?
A3: Yes. We provide OEM/ODM customization based on customer drawings, environments, and compliance needs.
Q4: Are Kehan’s products compliant with EU and US market regulations?
A4: Absolutely. All products are ROHS, REACH, and UL certified, meeting both EU and North American standards.
Q5: How do you ensure lightweight designs don’t affect conductivity?
A5: Through optimized conductor purity and thinner insulation in Lightweight Wiring Harness structures, we achieve both high conductivity and reduced weight.
? 6. Conclusion and Outlook
In the age of carbon neutrality and sustainable manufacturing, the wire harness industry is shifting from traditional to intelligent green manufacturing.
Kehan Electronics firmly believes:
“Every eco-friendly harness is a connection to a cleaner future.”
Moving forward, the company will continue investing in Advanced Materials Cable development, expanding innovation in wire harness technologies, and empowering global clients to build cleaner, smarter, and more efficient connection systems.
? Call to Action
Let’s build sustainable connections for a greener tomorrow.
Contact Kehan Electronics today for your custom eco-friendly wire harness solutions!
? Email: info@xmkehan.com
? Website: https://www.xmkhwire.com/contact