Consumers interested in electric vehicles typically assess range, safety ratings and high-tech features. However, they may not understand how advanced printed circuit boards contribute to the finished product.

EVs contain hundreds of PCBs. Although designs vary depending on their purpose, engineers make them as small and lightweight as possible. This supports the ongoing miniaturization trend that allows putting more innovations in smaller spaces to improve the vehicle’s range and performance. How have PCBs affected the EV market, and what does the future hold?

Facilitating Electrical Connections

PCBs enable essential connections between a car’s electrical components, affecting motor control, charging management and data transmission. They facilitate power distribution for the vehicle’s lights, driver assistance systems and other functions.

A July 2025 global analysis examined the electronic PCB connector and transformer market, confirming hybrid and electric cars’ substantial contributions to projected growth. The automobiles feature increasingly complex parts — such as electronic control units and power converters — that include printed circuit boards throughout the designs. The researchers expect the sector’s value to surpass $23 billion by 2032, with the North American market possessing a large share.

Additionally, the coverage detailed the rising demand for high-frequency transformers, including models for automotive powertrains. Many options attach directly to printed circuit boards, supporting power-dense applications in a small form factor. Similarly, this report positioned surface-mount PCBs as preferred for connectors because of their suitability for limited-size layouts. Their automated production system compatibility shortens fabrication time frames, too.

The authors cited thermal management and miniaturization issues as ongoing challenges. Advanced design tools, such as digital twins and cloud-based collaboration platforms, help engineers find and fix hot spots to prevent degraded performance and internal damage. They face supply chain shortages, especially if they require difficult-to-obtain raw materials. Long-term supplier relationships and bulk orders can alleviate availability concerns.

A recently released multilayer ceramic capacitor’s tiny size makes it small enough to fit on a pinhead. It is less than half the size of its predecessor but has twice the capacitance. These benefits enable simpler PCB layouts containing fewer components, giving engineers more space for advanced modules. Such innovations will keep PCBs in demand and increase versatility.

Accommodating the Automotive Industry

Engineers develop advanced PCBs to target specific features the automotive industry needs, such as moisture resistance or high-temperature tolerance. Since printed circuit boards last up to 20 years in modern vehicles, newer designs include innovative materials and coatings to lengthen longevity. Ongoing advancements should push the entire industry forward while PCBs continue to evolve in tomorrow’s automobiles.

Thermal management is an ongoing EV design concern. As experts plan to include PCBs in car-related innovations, many use digital modeling tools that let users try various layouts in controlled environments before prototyping them. Experimentation saves time and money by ruling out nonviable possibilities and revealing potential challenges for proactive troubleshooting. Inadequate trace positioning and electromagnetic interference commonly cause degraded performance, but models pinpoint problems early.

Engineers study other industries central to the world’s clean energy future to get ideas about incorporating PCBs that perform well in continually harsh environments. The solar and wind industry frequently manages expected loads with heavy copper and high-current PCBs to maintain performance. Similarly, geothermal power installations include metal core boards that handle challenging outdoor conditions and effectively dissipate heat.

Some PCBs target situations where the layouts cannot include heatsinks or fans due to the desired miniaturized designs. In 2024, a company offering five decades of experience in PCB design and fabrication released a version featuring rectangular or circular copper pieces arranged in a tiered orientation. It suggests placing one on the component’s bonding surface and another slightly thicker one on the heat-generating area.

The business targets these products for high-heat and high-current applications, mentioning how they can address miniaturization needs or mission-critical projects. Internal estimates found this design boosted component heat dissipation by up to 55 times, making it ideal for consideration in future EVs.

Maintaining Safety

Stringent PCB testing in simulated environments reveals how components will perform in the real world. Failing to catch issues in time causes recalls and risks lives. For example, Volkswagen Group EVs received reports of vehicles not charging correctly or owners having them towed into dealerships after sudden functionality losses. An investigation revealed the issue affected one Audi model and two Volkswagens and occurred because of PCB condensation buildup.

Engineers traced the cause to the DC/DC converter in integrated chargers after identifying the impact of various temperatures and humidity levels on the component. Many PCBs have moisture-protecting coatings. However, the ones in the defective cars had insufficient amounts, causing condensation buildup to gradually deactivate electrical systems. This issue affected an estimated 10% of the identified models.

The automaker addressed the problem by replacing the faulty parts with those containing a thick enough coating to safeguard delicate connections from moisture. Supplier quality control checks could prevent similar issues, rebuilding the affected brands’ reputations and convincing consumers that identified shortcomings should not discourage EV purchases. PCBs reinforce safety when produced to appropriate manufacturing standards.

For example, automotive radar PCBs help drivers maintain safe distances from motorists ahead of them, automatically adjusting the speed as needed. Printed circuit boards also have protective mechanisms that prevent short circuits or abnormal voltage and current levels. They cut the power to affected areas, preventing vehicular damage or accidents.

Built-in charging systems and recharging stations contain PCBs that address several needs to uphold safety and efficiency. They handle the conversion from alternating to direct current and maintain the necessary voltage to charge the battery at an effective but safe speed. However, high-power and fast-charging functions generate significant heat, requiring thermal management strategies and proactive layouts.

Keeping EV Manufacturers Relevant

As the electric vehicle marketplace becomes increasingly crowded, automotive brands must continue pushing the boundaries by announcing new designs and models. User-facing aspects get the most attention, bringing coverage in automotive blogs and encouraging consumers to schedule test drives.

PCBs are less immediately apparent, but people benefit from the continual functionality and appreciate it while using innovative safety features. They can charge their cars quickly and enjoy high-performance responsiveness thanks to these innovations.