Automotive Engineering - April 2023 - 6

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The Inside Story on Adapting to the Shift
Toward Electric Vehicles - Evolving Demands
for Engineered Fasteners in the Auto Industry
T
he shift toward electric vehicles (EVs) in the automotive industry has led to changes in the design and construction
of vehicles, including the use of new materials, new technologies and new standards. One area that has seen
significant changes is the use of engineered fasteners, which are used to hold together the various parts of a vehicle.
As EVs have different requirements than internal combustion engine vehicles, OEMs are now requesting different
types of fasteners with unique features such as larger holes, higher extraction forces and oval shape.
Bernardo Heiremans, Auto & Cable Ties Product Manager in Avery Dennison's Fasteners Division, discussed with SAE's
Automotive Engineering how the company has responded to these changes by developing a complete portfolio of oval
clips to meet these new demands.
With the transition to EVs, is there a
change in the type of engineered
fasteners being requested by OEMs?
Yes, for EV applications, OEMs are
demanding more-advanced and specialized
fasteners to accommodate
the larger and heavier wiring harnesses
used in these vehicles. In the past,
the 6.6-mm round hole was the standard
size for internal-combustion engine
vehicles, with panel thicknesses
ranging from 0.7 mm to 7 mm.
However, now many OEMs are moving
from round holes to oval holes for
better retention and to prevent rotation
of the fastener. Additionally, in
2021 USCAR released a new 9x17-mm
heavy-duty hole size, which is becoming
popular for new EV platforms.
This new size requires higher extraction
forces to ensure the safety and
proper retention of the harness within the vehicle.
with aluminum. Although aluminum is
lighter than steel, it also is weaker. To
address this, manufacturers have
been increasing the thickness of aluminum
panels. Previously, the maximum
panel thickness was 7 mm, but
now there are requests for panels as
thick as 10 mm or even 12 mm. To
support these thicker panels, new
fastening solutions have been developed,
such as the 9x17 clip, which can
be used in panels up to 12-mm thick
and paired with a heavy-duty strap
for added support and strength for
the harness.
Bernardo Heiremans, Avery Dennison Auto &
Cable Tires Product Manager, Fasteners Division.
What steps has Avery Dennison taken
to adapt to recent changes in the
automotive industry?
Avery Dennison has developed a
comprehensive portfolio of oval clips
What is the chief reason for larger holes on EVs?
The reason for larger holes on EVs is due to the thicker
cables and larger bundle diameters that are used in these
vehicles. This results in heavier harnesses that require
more-secure fastening methods. Using a traditional fir tree
fastener with a 6.6-mm hole and a minimum extraction
force of 25 lbs. - as specified by USCAR 44 - may not be
sufficient to hold the harness securely in place. However,
by using a larger 9x17-mm hole and an Avery Dennison fir
tree fastener, the harness is held securely with a minimum
extraction force of 50 lbs. This ensures the safety and integrity
of the harness in the EV.
You previously mentioned panel thicknesses, are there
any changes there?
OEMs are constantly seeking ways to make vehicles lighter
and more efficient, one of which is replacing steel chassis
6 April 2023
to meet the changing needs of the industry. This includes
clips for 6.5x12.5-mm holes in standard, 12.5-mm and 25mm
standard and reverse offsets, a 2-piece option for use
with heavy-duty and standard straps, and a long, 2-piece
option for panel thicknesses of up to 16 mm.
What other strategies are available to improve the construction
of EV harnesses?
Efficiency is a crucial aspect for any company, and this
applies to the use of fasteners as well. By reducing the
number of types of fasteners used, it can lead to a more
efficient supply chain for the procurement team - and
cost savings due to the reduction of parts in the bill of materials.
Avery Dennison's parts are designed to fit multiple
hole sizes and our experts can provide customers with alternative
solutions to reduce the number of parts used, as
well as other cost-saving ideas. For more information, customers
can access Avery Dennison's online catalog of fasteners
at: fasteners.averydennison.com.
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Automotive Engineering - April 2023

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