Sign In or Create an Account.

By continuing, you agree to the Terms of Service and acknowledge our Privacy Policy

Electric Vehicles

Why EV-Makers Are Suddenly Obsessed With Wires

Batteries can only get so small so fast. But there’s more than one way to get weight out of an electric car.

•
A Rivian having its wires pulled out.
Heatmap Illustration/Rivian, Getty Images

Batteries are the bugaboo. We know that. Electric cars are, at some level, just giant batteries on wheels, and building those big units cheaply enough is the key to making EVs truly cost-competitive with fossil fuel-burning trucks and cars and SUVs.

But that isn’t the end of the story. As automakers struggle to lower the cost to build their vehicles amid a turbulent time for EVs in America, they’re looking for any way to shave off a little expense. The target of late? Plain old wires.

Last month, when General Motors had to brace its investors for billions in losses related to curtailing its EV efforts and shifting factories back to combustion, it outlined cost-saving measures meant to get things moving in the right direction. While much of the focus was on using battery chemistries like lithium ion phosphate, otherwise known as LFP, that are cheaper to build, CEO Mary Barra noted that the engineers on every one of the company’s EVs were working “to take out costs beyond the battery,” of which cutting wiring will be a part.

They are not alone in this obsession. Coming into a do-or-die year with the arrival of the R2 SUV, Rivian said it had figured out how to cut two miles of wires out of the design, a coup that also cuts 44 pounds from the vehicle’s weight (this is still a 5,000-pound EV, but every bit counts). Ford has become obsessed with figuring out smarter and cheaper ways for its money-hemorrhaging EV division to build cars; the company admitted, after tearing down a Tesla Model 3 to look inside, that its Mustang Mach-E EV had a mile of extra and possibly unnecessary wiring compared to its rival.

A bunch of wires sounds like an awfully mundane concern for cars so sophisticated. But while every foot adds cost and weight, the obsession with stripping out wiring is about something deeper — the broad move to redefine how cars are designed and built.

It so happens that the age of the electric vehicle is also the age of the software-defined car. Although automobiles were born as purely mechanical devices, code has been creeping in for decades, and software is needed to manage the computerized fuel injection systems and on-board diagnostic systems that explain why your Check Engine light is illuminated. Tesla took this idea to extremes when it routed the driver’s entire user interface through a giant central touchscreen. This was the car built like a phone, enabling software updates and new features to be rolled out years after someone bought the car.

As Tesla ruled the EV industry in the 2010s, the smartphone-on-wheels philosophy spread. But it requires a lot of computing infrastructure to run a car on software, which adds complexity and weight. That’s why carmakers have spent so much time in the past couple of years talking about wires. Their challenge (among many) is to simplify an EV’s production without sacrificing any of its capability.

Consider what Rivian is attempting to do with the R2. As InsideEVs explains, electric cars have exploded in their need for electronic control units, the embedded computing brains that control various systems. Some models now need more than 100 to manage all the software-defined components. Rivian managed to sink the number to just seven, and thus shave even more cost off the R2, through a “zonal” scheme where the ECUs control all the systems located in their particular region of the vehicle.

Compared to an older, centralized system that connects all the components via long wires, the savings are remarkable. As Rivian chief executive RJ Scaringe posted on X: “The R2 harness improves massively over the R1 Gen 2 harness. Building on the backbone of our network architecture and zonal ECUs, we focused on ease of install in the plant and overall simplification through integrated design — less wires, less clips and far fewer splices!”

Legacy automakers, meanwhile, are racing to catch up. Even those that have built decent-selling quality EVs to date have not come close to matching the software sophistication of Tesla and Rivian. But they have begun to see the light — not just about fancy iPads in the cockpit, but also about how the software-defined vehicle can help them to run their factories in a simpler and cheaper way.

How those companies approach the software-defined car will define them in the years to come. By 2028, GM hopes to have finished its next-gen software platform that “will unite every major system from propulsion to infotainment and safety on a single, high-speed compute core,” according to Barra. The hope is that this approach not only cuts down on wiring and simplifies manufacturing, but also makes Chevys and Cadillacs more easily updatable and better-equipped for the self-driving future.

In that sense, it’s not about the wires. It’s about all the trends that have come to dominate electric vehicles — affordability, functionality, and autonomy — colliding head-on.

Blue
🔒

You’ve reached your free article limit

Subscribe to Heatmap News for unlimited access to daily energy and climate coverage.
To continue reading
Create a free account or sign in to unlock more free articles.
or
Please enter an email address
By continuing, you agree to the Terms of Service and acknowledge our Privacy Policy
Energy

Net Power Surrendered Its Clean Dreams to Data Center Demand

The zero-emission pioneer is doing the dirty work for the AI boom.

A gas plant and a data center.
Heatmap Illustration/Getty Images

All kinds of companies have refashioned themselves to exploit the AI boom. A bitcoin miner became a data center developer, a shoemaker is building GPUs, and an electric vehicle company is integrating its powertrains into server racks.

Now, a company that once aspired to build one of the lowest-emitting power plants has pivoted to building one of the dirtiest in order to meet data centers’ requirement for speed to power above all. Net Power was founded to pioneer a new form of natural gas power plant with zero emissions, but it has given up on that technology and recently acquired 10 natural gas reciprocating engines that it plans to co-locate with a data center on the site intended for its first commercial plant.

Keep reading...Show less
Yellow
Politics

The Surprisingly Exciting Race to Be California’s Next Insurance Commissioner

Ben Allen wants to reform the existing market. Jane Kim wants a revolution.

California Insurance Commissioner candidates.
Heatmap Illustration/Getty Images, Ben Allen, Jane Kim

From Crescent City to Coronado, California voters are facing decisions on a down-ballot strewn with over a dozen propositions and a series of statewide Democrat-versus-Republican races with mostly foregone conclusions.

And then there’s the insurance commissioner.

In the race to oversee California’s insurance market, a $452 billion-in-premium-volume monster imperiled by insurer defections and disaster risks, Democratic State Senator Ben Allen, whose district includes Pacific Palisades, is facing off against Jane Kim, a progressive former San Francisco supervisor.

Kim has the support of Vermont Senator Bernie Sanders — it’s the first thing you see about her when you Google her campaign. She previously served as his California political director during the 2020 presidential race, and she appeared earlier this month at an event with the senator in support of the state’s proposed billionaire wealth tax.

Allen, by contrast, won the endorsement of the state’s Democratic Party and its two incumbent senators.

There has been little public polling of the race, but one September survey showed Kim leading Allen 25% to 18%, with more than half the electorate undecided.

“My opponent and I are not even running for the same office,” Kim told me. “He’s running for what this office used to be, and I’m running for what this office could be.”

Allen wasn’t worried about Kim’s characterization in my interview with him, telling me, “I want to fix the market that we have and make it work. My opponent wants to build a new state insurer that nobody has priced.”

Keep reading...Show less
AM Briefing

The Solar Stockpiler Smackdown

On Hungary’s Russian nuclear conundrum, why geothermal isn’t solar, and a funny use of gallium

Solar panels.
Heatmap Illustration/Getty Images

Current conditions: An ill-timed and dense fog blanketed Toledo yesterday amid an industrial chemical leak, with the low-lying cloud acting to trap the toxic glycidyl methacrylate in the air, forcing an evacuation • Super Typhoon Champi has become the most powerful storm of 2026 as it roars westward across the Pacific to Taiwan, leaving a damaged Guam in its wake • After Polo, Simon, Rachel, and Trudy, yet another tropical depression capable of striking western Mexico as a major hurricane has formed in the eastern Pacific.


THE TOP FIVE

1. ‘This is how you blow up a permitting deal’

That’s the money quote Politico nabbed Wednesday from Senator Sheldon Whitehouse, the Rhode Island Democrat who helped broker the Senate’s grand compromise to ease federal permitting on energy projects. The statement came a day after the Department of Justice filed a petition to reopen the permits on New England Wind, the 2.6-gigawatt offshore wind project from Avangrid. Just over a week ago, the Trump administration restarted a legal fight with Orsted over Revolution Wind, which is already generating electricity off the coast of Rhode Island. At the time, some White House observers saw the effort as President Donald Trump’s hard-nosed negotiating, designed to pressure skeptical Democrats into voting for the legislation lest the administration continue going after projects that the bill, if passed, would protect. But Ira Joseph, a fellow at Columbia University’s Center on Global Energy Policy, saw the latest move as evidence Trump can’t control his impulse toward vendetta. “An inevitable turn. It’s always personal and never about what policy would either benefit or hurt the public,” he wrote in a post on X. “Wind will always be associated with harming the family business. It’s always a King Claudius situation and he or she who whispers last, whispers loudest.”

Keep reading...Show less
Yellow