High Voltage in Steel: How the E-Revolution is Reinventing the Wire Industry

The transformation of the automotive industry toward electromobility represents a fundamental change that directly affects the steel industry. New material requirements, changed production volumes, and innovative areas of application characterize this structural transformation. 

Impact on the German Steel Industry 

The German steel industry finds itself in a challenging phase. While crude steel production closes with an increase of around 5% compared to the previous year, the crude steel volume produced remains below the 40 million ton threshold for the third consecutive year, thus at recession level. This development directly reflects the structural changes in the automotive industry as well. 

E-mobility fundamentally changes the demand for steel products. While conventional vehicles primarily rely on mass steel for body parts, electric vehicles require specialized steel grades and new product categories. Particularly affected are high-strength steels (AHSS - Advanced High Strength Steel) for battery housings, which must simultaneously ensure crash safety and weight optimization. 

The shifts in steel demand are also reflected in economic indicators: Order intake in the steel industry fell by 9.4% in the third quarter of 2024 compared to the previous quarter. This development results partly from the transition to new product categories as well as changed purchase volumes in the automotive industry. 

Steel Products in the Modern Automotive Industry 

Nevertheless, despite the e-mobility transformation, the automotive industry remains the largest customer of the steel industry. Modern vehicles, whether electrically or conventionally powered, continue to require a growing number of specialized steel products: 

Body steels and structural components: High-strength and ultra-high-strength steels (AHSS, UHSS) form the backbone of modern vehicle structures. They enable thinner wall thicknesses while simultaneously improving crash safety and reducing weight. 

Battery housings and structural parts: Electric vehicles require robust protective structures for battery systems. Special steels are used here that combine high strength with optimal weldability. 

Chassis components: Springs, damper parts, and stabilizers made of high-strength spring steels must meet the changed weight distributions and load patterns of e-vehicles. 

Drive components: Precision steels for transmission parts, bearings, and motor components are also indispensable in electric vehicles. 

Wire Products in E-Mobility: New Dimensions of Application 

Wire products are experiencing both a renaissance and reorientation through electromobility. Traditional areas of application are expanding to include innovative fields of use that pose specific material requirements. 

Tire Reinforcement and Cord Technology 

E-mobility, for example, places entirely new demands on tire technologies. Electric vehicles exhibit changed load profiles due to their higher weight and instant torque. This requires optimized steel cord solutions for tire reinforcement. 

Companies such as ArcelorMittal and Bekaert have specifically aligned their WireSolutions product lines to these requirements. Modern steel cords for e-vehicle tires must exhibit higher tensile strengths while simultaneously improving fatigue resistance. Bead wire technology for tire beads has also been further developed to withstand increased mechanical loads. 

Continental and other tire manufacturers are working on specialized e-vehicle tires that offer optimized rolling resistance for greater ranges. These developments require precisely coordinated wire products with defined surface properties and strength profiles. 

Battery Housings and Fastener Technology 

The battery systems of electric vehicles require high-precision fastening elements and mounting systems. Specialized cold-formed wires and fastener solutions are used here, which must ensure maximum reliability under extreme temperature conditions. 

Companies such as Bulten have aligned their product development to the specific requirements of e-mobility. Battery fastenings must not only absorb mechanical loads but also ensure electrical insulation and compensate for thermal expansion. 

voestalpine Wire Austria develops EPD (Environmental Product Declaration)-certified cold heading wires that meet the sustainability requirements of the automotive industry. These products are characterized by reduced CO₂ emissions in production and optimized recyclability. 

Chassis and Suspension Systems 

Electric vehicles pose new requirements for suspension systems due to their changed weight distribution. Mubea, as a leading manufacturer of coil springs, has developed special coil spring systems for e-vehicles that account for the increased loads from battery weight. 

The optimization of spring wire properties is achieved using advanced simulation techniques. Ansys simulations enable precise tuning of spring characteristics to the specific requirements of various e-vehicle platforms. In addition to mechanical load capacity, aspects such as NVH (Noise, Vibration, Harshness) are also in focus. 

Wire Rod and Customized Solutions 

voestalpine Wire Technology positions itself as a complete provider for mobility solutions and offers specialized wire rod grades for e-vehicle applications. Spring steel wires according to the EN 10089 standard, which are used for highly stressed spring elements in e-vehicles, are of particular importance. 

ArcelorMittal continuously expands its WireSolutions portfolio with e-mobility-specific products. Development takes place in close collaboration with automotive manufacturers and considers the entire value chain from crude steel production to final application. 

Welding and Joining Technology 

The assembly of e-vehicle components requires specialized welding wires and joining technologies. voestalpine Böhler Welding develops solid wires and cored wires specifically for the requirements of electromobility. Aspects such as welding different materials, integration of lightweight materials, and ensuring electrical insulation are in the foreground. 

Steel battery housings, as developed by Fraunhofer IPK, require high-precision welding technologies. The welding wires used must have defined chemical compositions to ensure the required mechanical and electrical properties of the welded joints. 

New Standards and Quality Requirements 

E-mobility is moreover establishing new industry standards and quality requirements that have direct effects on wire production. In addition to established automotive standards, e-mobility-specific requirements are emerging: 

Electrical properties: Wire products in e-vehicles must exhibit defined electrical conductivities or insulation properties, depending on their application. 

Thermal resistance: Components near battery systems must cover extended temperature ranges and withstand thermal cycling loads. 

Sustainability certifications: EPD certifications and CO₂ footprints are becoming decisive quality criteria in supplier selection. 

Traceability: Comprehensive documentation of material origin and properties is becoming a prerequisite for integration into e-vehicle production lines. 

Opportunities and Challenges of Change 

Advantages of the E-Mobility Transformation: 

Product differentiation: Specialized wire products for e-mobility applications enable higher margins and stronger customer loyalty. 

Innovation leadership: Companies that invest early in e-mobility technologies can establish themselves as market leaders in new segments. 

Sustainability image: Supporting the e-mobility transformation strengthens the sustainability profile of steel manufacturers in general. 

Global markets: E-mobility is a worldwide trend that opens up new export opportunities. 

Electrical Energy, Steel, and Strategy: The Transformation of the German Wire Industry 

Electromobility catalyzes a fundamental change in the steel industry and opens up new perspectives for wire products. While traditional applications are being replaced or supplemented by innovative solutions, entirely new market segments with specific requirement profiles are emerging. 

Successfully navigating through this transformation requires strategic foresight, technical innovation, and operational excellence from companies. Companies that invest early in e-mobility-specific competencies and align their product portfolios accordingly will benefit from long-term growth perspectives. 

The German steel industry faces the task of combining its traditional strength in precision manufacturing with the innovation requirements of e-mobility. This is achieved through intensive cooperation with automotive manufacturers, consistent sustainability orientation, and the continuous development of future-proof wire solutions for the mobility of tomorrow. 

Learn more about wire in the electro-automotive industry at the next wire & Tube, which will take place from April 13 to 17, 2026 in Düsseldorf. Current industry and product information is available on the internet portal at www.wire.de.