Electric Wiring Interconnection Systems Market Size & Share Analysis - Growth Trends And Forecast (2025 - 2030)

Global Electric Wiring Interconnection Systems Market Trends and Insights

Surging Global Aircraft Production Backlog

Order books at major OEMs exceeded 12,000 units by early 2025. COMAC stated that it would double the number of C919 hand-offs to 30 jets by 2025, while managing more than 1,000 commitments, thereby reinforcing long-term visibility for cable and connector suppliers. HAL received 97 additional Tejas Mk1A orders in April 2025 under a contract worth INR 65,000 crore (approximately USD 7.8 billion), which specified 65% local content, thereby amplifying regional sourcing for the harnesses. The backlog extended to military programs, such as India’s Advanced Medium Combat Aircraft (AMCA), which is targeted for 126 deliveries by 2047, ensuring sustained demand for EWIS market suppliers.

Transition to More-electric and Hybrid-electric Aircraft

Boeing’s B787 architecture eliminated bleed-air plumbing and integrated six generators, reducing engine parasitic loads by 35% and increasing onboard electrical power, which required higher current-capacity harnesses with robust EMI protection. Analytical studies indicated that combining more-electric subsystems with hybrid propulsion could reduce trip fuel consumption by 10%, provided the wiring could handle elevated voltages without thermal runaway. eVTOL start-ups pushed further, with TE Connectivity unveiling lightweight avionics connectors for 800V platforms, demonstrating the evolution path for the EWIS industry.

Tightening EWIS-specific Aviation Safety Mandates

The FAA’s Part 25 Subpart H rules, reinforced in 2024, required system separation, fire resistance, and accessibility provisions that limited catastrophic failure probability to “extremely improbable” rates. EASA mirrored these expectations via AMC 20-22, and an FAA directive issued in September 2024 mandated the addition of bonding straps on 292 B777 jets to eliminate the refuel-spark risk.^{[1]Source: Federal Register, “AD 2024-20390 Boeing 777,” federalregister.gov} Compliance accelerated retrofit activity, directly supporting the EWIS market.

High-speed IFEC Data Networks Demanding New Cabling

Airlines installed gigabit-class cabin networks to stream 4K content and enable real-time analytics. Fiber-optic lines delivered more than 100 Gb/s throughput while shedding weight versus conventional copper, and Gore’s cables met ARINC performance at tight bend radii. ITT Cannon launched the OctoGig and Quadrax Ethernet connectors, which balance shielding, density, and ease of termination for retrofit programs. The requirement for bandwidth-rich IFEC infrastructure thus lifted premium-grade demand inside the EWIS market.

Copper and Specialty-alloy Price Volatility

Spot copper prices reached USD 5.20 per pound in May 2024, prompting cable suppliers to impose surcharges of up to 45%. Rhenium and niobium markets likewise tightened, and recycling could meet only 30% of rhenium demand by 2025. OEMs, therefore, hedged their inventories and evaluated aluminium or composite conductors, which affected near-term pricing in the EWIS market.

Move Toward Wireless Avionics Networks

Academic prototypes showed that low-power IEEE 802.15.4 sensor meshes could shave wiring weight while maintaining redundancy for non-safety-critical links. Yet, certification for airborne wireless in flight-critical zones remained arduous, and EMI compliance kept copper and fiber entrenched. The shift, therefore, acted as a long-horizon drag rather than an immediate threat to the EWIS market.

Segment Analysis

By Component: Mature Wire Dominance With Connector Acceleration

Wires and cables accounted for 37.53% of 2024 revenue, underscoring their role as the backbone of modern aircraft's power distribution, flight control, and data lines. Demand for these conductors rose steadily as more-electric platforms added higher-voltage secondary buses that required thicker gauges and improved insulation systems. Connectors and accessories nevertheless advanced at a 5.65% CAGR because OEM engineering teams standardised plug-and-play modules that cut assembly hours on the final line while boosting maintainability during heavy checks. The trend was reinforced by rising retrofit activity, where quick-disconnect connectors reduced downtime for cabin upgrades and line-replaceable-unit swaps. Overall, the mix highlighted complementary growth paths for core wire products and high-value interconnect hardware.

High-speed data and voltage uprating simultaneously drove innovation across both sub-segments. Gore's GWN 3000 family introduced fluoropolymer jackets that withstood tighter bend radii and 260 °C hotspots without signal loss, enabling 100 Gb/s fiber backbones alongside traditional copper bundles.^{[2]Source: W. L. Gore & Associates, “High-Performance Aerospace Wires,” gore.com} TE Connectivity responded with lighter stamped-and-formed contacts for eVTOL motor controllers, shaving grams in weight-critical applications, highlighting a benefit magnified when multiplied across thousands of terminations per airframe. FAA bonding directives on 292 B777 jets further lifted demand for clamps, pressure seals, and anti-chafe sleeving as operators complied with electrostatic-discharge rules. Together, these forces broadened the revenue mix inside the EWIS market and encouraged suppliers to extend vertically into accessories, tooling, and installation services.

Note: Segment shares of all individual segments available upon report purchase

By Platform: Fixed-wing Scale Meets eVTOL Disruption

Fixed-wing programs held a 65.50% market share in 2024, as single-aisle, wide-body, and regional-jet lines dominated global delivery volumes. Each new build required 200 km of wiring, locking in large unit opportunities for harness integrators and raw-material vendors. Although still nascent, the UAM segment recorded the fastest percentage growth of 9.10%, following Archer and GKN's 2025 supply contracts for low-voltage looms on the Midnight air taxi, signaling the start of scalable industrialization in the eVTOL domain. Business jet and turboprop platforms added incremental demand, especially for Ka-band connectivity kits that raised cabin data rates and required shielded quadrax cables. Consequently, platform diversification cushioned suppliers against cyclical swings in any aircraft category while enhancing the long-term outlook for the EWIS market.

Military rotorcraft and civil helicopters preserved baseline volumes because fleet recapitalisation programs mandated crash-resistant fuel systems and new avionics that triggered loom redesigns. Regulatory upgrades focused on occupant survivability stimulated retrofits, bolstering rotary demand and sustaining specialist harness shops that specialize in short-run, high-complexity projects. In contrast, eVTOL certifications with 10⁹ catastrophic-failure probabilities compelled early entrants to adopt aerospace-grade wiring, connectors, and overbraids rather than automotive substitutes, thereby prolonging the relevance of incumbent manufacturers. Hybridisation of powertrains on tilt-rotor and lift-plus-cruise models added further cable runs for battery conditioning and high-power distribution, raising content per aircraft. The coexistence of legacy fleets and next-generation air taxis ensured a balanced yet dynamic growth trajectory across the EWIS market.

By Application: Airframe Base, IFEC Sprint

Airframe wiring accounted for 30.45% of 2024 revenue, as primary flight-control, anti-ice, and fuel-pump circuits remain non-negotiable for safe operations. Fleet life-extension programs on narrow-body families maintained this baseline resilience by replacing aging bundles that no longer met insulation-resistance limits. Cabin and IFEC cables, however, posted the highest 8.02% CAGR as airlines raced to match passenger expectations for gate-to-gate streaming and real-time messaging. Large twin-aisle retrofits often added more than 50 additional fiber channels per aircraft, materially enlarging the EWIS market size at cabin-level projects. Growth also came from premium-economy densification, which required additional seat power outlets, mood lighting strings, and smart-galley equipment.

Deploying fiber-optic backbones reduced noise susceptibility, freed weight, and unlocked predictive-maintenance data off-loads for operators pursuing turnaround-time savings. Avionics and mission-system wiring maintained steady mid-single-digit growth because AI-assisted sensors expanded pin-count density, requiring gigabit interconnects to backhaul raw data to flight computers. Propulsion wiring benefited from the adoption of starter-generators on geared-turbofan lines, where higher amperage drew in new aluminum-core conductors with fire-resistant sheaths. Power-distribution looms also migrated toward higher-voltage direct-current architectures, shifting connector specifications and increasing demand for arc-fault protection. These overlapping requirements demonstrated how advancements within the EWIS market touched and enabled every subsystem.

Note: Segment shares of all individual segments available upon report purchase

By End-User: OEM Scale, Aftermarket Momentum

OEM deliveries accounted for 75.60% of 2024 revenue, as line-fit harnesses are procured directly by Airbus, Boeing, and other primes during final assembly. The sheer scale of single-aisle build rates, bolstered by record order books, ensured predictable annual volumes for tier-one harness integrators. Boeing sourced over USD 1 billion annually from Indian partners. Airbus engaged over 100 local firms for sub-assemblies, embedding localisation and offset clauses inside the EWIS market. Production system modernisation, such as digital thread traceability, further tightened collaboration between primes and wiring specialists to reduce rework and improve first-pass yield. As eVTOL programs transitioned from prototypes to type certification, green-field OEMs also began entering into multi-year hardware agreements, thereby broadening the customer pool for established suppliers.

Aftermarket demand grew at a 7.20% CAGR because airlines pursued avionics, cabin, and connectivity retrofits to refresh mid-life fleets. The 2024 American Airlines–Airbus contract to upgrade 150 A320ceo jets illustrated how a single deal could generate thousands of line items for replacement looms, brackets, and connectors. Mandatory EWIS inspection intervals under 14 CFR 26.11 also expanded workload for MRO shops by obliging operators to document zonal-analysis procedures and replace degraded bundles. Lease-return conditions prompted carriers to install ADS-B Out, FANS 1/A, and SBAS receiver upgrades, each requiring new wire runs between the new LRUs and existing junction boxes. Collectively, these factors highlighted the growing strategic importance of aftermarket revenue streams for wiring suppliers.

Geography Analysis

North America retained 38.65% of 2024 revenue. The FAA’s early enforcement of EWIS rules, combined with Boeing’s extensive supplier base, kept the region at the forefront of the EWIS market.

Asia-Pacific posted a 6.60% CAGR to 2030. COMAC doubled its C919 output plans, and HAL recorded rolling Tejas and AMCA backlogs, unlocking wider regional opportunities for manufacturers that met the Make-in-India thresholds. Component MRO joint ventures, such as Eaton-SIAEC in Malaysia, further scaled regional aftermarket capacity.

Europe leveraged CleanSky2 goals, which aimed for 20-30% CO₂ cuts through the use of thermoplastic fuselages, requiring integrated wiring channels. This encouraged suppliers like Safran, whose revenue rose 16.7% year-over-year in Q1 2025, to expand their harness facilities across France, Morocco, and Mexico.^{[3]Source: Safran Group, “Q1 2025 Revenue Release,” safran-group.com} The EWIS market, therefore, balanced mature Western demand with accelerated Eastern expansion.