The on-board network forms the nervous system of modern vehicles and is facing major challenges due to new drive technologies, increasing networking and autonomous driving. The development of vehicle wiring harnesses is becoming increasingly complex as fragmented data landscapes and inhomogeneous structures complicate the processes.

In the BordNetzSim3D research project, fleXstructures developed a consistent digital solution together with partners such as Fraunhofer ITWM, Volkswagen and WeWire. BordNetzSim3D focused on the redesign of a digital, physics-based on-board network development process. The aim was to achieve a high degree of automation and to optimize efficiency in power set development. An important component is the collaboration hub, a digital platform that enables seamless integration into customer systems and ensures consistent data processing across different disciplines.

The physics-based design approach uses IPS Cable Simulation and combines a wiring system-specific component library with digital tools such as topological 3D routing and 3D flattening. The latter enables, for the first time, a realistic generation of the power set and the associated form board in one step, thereby avoiding iteration loops, shortening development times and significantly increasing the overall efficiency of the wiring system design.

The lecture by Michael Koch, Technical Director & Research Coordinator, fleXstructures GmbH, took place on 28 January 2025 as part of the trend outlook instead.