Q&A: Why 48V Architecture?

As vehicles become more electrified and software-defined, the demands on traditional 12V electrical architectures continue to grow. ADAS, electric actuators, steer-by-wire technologies and other high-power applications are pushing conventional systems to their limits. In a recent three-part podcast series hosted by TTI , Aptiv Senior Application Engineer Nityesh Bohidar explained why 48V architectures are gaining momentum, the benefits they offer and what OEMs should consider when making the transition. Here are some key questions he addressed.

Why is the automotive industry considering a shift from 12V to 48V electrical architectures?

The power demands of modern vehicles have increased dramatically over the past several decades as new features have emerged, from new cameras and radars being used for driver assistance, to mechanical loads being swapped, to electrical loads. The move toward features such as steer by wire, brake by wire and adjustable suspensions are all contributing to the increase in electrical loads on today’s vehicles. This surge in demand strains 12V systems, making 48V a logical next step to reduce current.

What are the key advantages of moving to 48V?

A 48V architecture reduces current by a factor of four compared to a 12V system delivering the same amount of power. Lower current enables the use of smaller wires and terminals, reducing vehicle weight, copper usage and packaging complexity. Smaller cables are easier to route through crowded vehicle structures and openings. In addition, 48V systems can reduce resistive power losses up to 16 times, improving overall power and electrical efficiency.

Is 48V considered safe?

Yes. A 48V system is below the 60V threshold that is generally recognized as high voltage and is considered safe from electric shock hazards. This makes 48V a sweet spot that delivers significant efficiency and packaging benefits without introducing the additional safety requirements associated with high-voltage systems.

What design considerations are unique to 48V systems?

While 48V systems share many similarities with traditional architectures, they introduce new design considerations to avoid arcing and electrochemical corrosion. Arcs at 48V carry more energy and can last longer than those at 12V, potentially damaging connectors. Connector designs must account for creepage and clearance distances to help prevent unintended electrical discharge between conductors.

OEMs must also carefully separate 12V and 48V circuits to protect lower-voltage components in the event of a ground fault. Robust terminal systems with reliable secondary locks and sealing to protect connectors from environmental exposure are equally important to ensure long-term reliability and safety.

Which vehicle applications benefit most from 48V?

The maximum benefits are found in higher-power applications where larger cables are typically required, such as steering systems, braking systems, HVAC blowers, seat motors, roll stabilization systems and window heaters.

Lower-power features, such as infotainment systems and lighting, will often continue to operate on 12V because wire sizes for these applications are often determined by mechanical durability requirements rather than electrical load. As a result, many vehicles are expected to use multi-voltage architectures that combine both 12V and 48V.

Beyond automotive, where else is 48V gaining adoption?

Industries such as robotics, energy storage, marine applications, commercial transportation and industrial equipment are increasingly adopting 48V solutions to reduce copper usage and cost, improve packaging flexibility and support growing power requirements. The concept of using a higher voltage to reduce wire size applies across all industries.

As these industries continue to electrify, 48V offers a balance between performance, efficiency and safety, making it an appealing standard for a wide range of applications.

How is Aptiv enabling the transition to 48V?

Aptiv offers a broad portfolio of connectors designed specifically for 48V applications. These products can be color-coded for voltage identification and are engineered to meet creepage and clearance requirements, provide environmental protection through robust sealing systems, and include safety features, such as Connector Position Assurance and secondary terminal locks.

We are developing solutions aligned with emerging standards, including the Low-Voltage Connector Standard, helping customers implement scalable and future-ready 48V architectures. In addition, we participate in industry standards organizations such as USCAR and ISO, collaborating with other leaders to help us anticipate emerging trends and ensure our solutions are ready as new requirements are introduced.