Automotive mega trends, such as electrification, autonomous driving and safety features, as well as high-speed and wireless connectivity, are not only persisting, but becoming more widespread. Published in January 2021, a Molex survey of 230 qualified decisionmakers at automotive OEMs revealed that 91% believed the “car of the future” will be fully electric or hybrid. Additionally, 94% think it will include autonomous driving features and that high-speed Wi-Fi and wireless charging will be its most popular features. In fact, safety and driver empowering systems, such as larger displays, camera systems and detection sensors like LIDAR, are increasing on nearly all models. These trends are also encouraging engineers to increase the capabilities of these features while powering them with denser and smaller components.

To aid in this rapid expansion of new and evolving electronic systems, designers are driven to miniaturize and, as a result, seek out new components and interconnect technologies. Often, designers have turned to components and interconnects that are common to mobile and consumer electronics. However, while micro components alleviate space constraints in a car designs, they also will need to prove reliability in these rugged applications. Also, in order to meet their customers’ expectations, automotive OEMs and their suppliers require a certain level of electronic component excellence, including wide temperature ratings, shock and vibration validation, along with adherence to Automotive Production Part Approval Process (PPAP).

As automotive designers are placing more and bigger LCD screens throughout vehicle interiors, traditionally used interconnect systems such as wire-to-board connectors are being replaced by compact, fine-pitch flexible cable (FFC/FPC) connectors. These connector systems support higher pin counts, higher frequencies, increasing component density and need for precise alignment. By enabling automated assembly and offering higher component densities that make room for new value-added electronic features, FPC connector systems also can make economic sense.

In addition to backup vision, cameras are being added to vehicles at increasing levels each year. Autonomous and safety driving features in particular use data retrieved from cameras and sensors. Because many cameras and sensors are placed on the outside of the car, their components must endure harsh environments to ensure reliable connectivity. Designers need to protect sensitive camera connector interfaces, which can be exposed to temperature extremes, vibration, shock, as well as moisture and contaminants – These safety systems cannot fail, so protecting these interfaces is of high value to system designers.

As our homes and workplaces become ever more connected, drivers and passengers expect the same in their vehicles. Wireless charging, high-speed data and Wi-Fi are expected by today’s car purchasers. A single USB port is no longer enough. As fast-charging over USB Type-C becomes widespread, consumers will expect multiple ports on the dashboard and in the backseat.

As cars become mobile computing platforms, more components and PCBs will be present in automotive designs. These electronics will need to be able to withstand vibration and mitigate stress on solder joints that could affect performance and even cause failure, requiring the module to be replaced.