E-Systems

Powerful. Compact. Efficient.
Driving the future of mobility.

Lear is the automotive leader in power management and signal distribution for all types of powertrains, including established, growing and future forms of mobility.

We design, develop, engineer and produce customizable, scalable and innovative solutions for the world’s top automakers.

Electrical Distribution & Connection Systems Electronic Solutions Operational Excellence

Electrical Distribution & Connection Systems

A sophisticated and scalable electrical highway, our Electrical Distribution and Connection Systems route network and data signals while managing power throughout the vehicle. Our portfolio of automotive terminals, connectors, and engineered components delivers high-performance, ultra-compact, and lightweight solutions with the highest power in the industry.

Wire Harnesses

Lear’s wire harnesses link all of the electric and electronic devices within the vehicle to each other and/or a power source. They support both low-voltage systems (12–48V) for light-duty vehicles and high-voltage systems (60–800V) for electrified powertrains.

Lear’s lightweight solid aluminum harness was among Automobilwoche’s Top 25 Products to Watch in 2024. Our innovative solution reduces weight up to 35%, enhances efficiency, and can be retrofitted into existing connection systems. Engineered to deliver more power in a smaller package, a single ½-inch terminal can handle more power than an entire modern household.

Connection Systems

Lear’s electrical distribution and connection systems form a sophisticated, scalable highway for power and data throughout the vehicle. Supporting low-voltage, high-voltage, and high-speed data applications, our solutions deliver compact, lightweight, and high-performance connectivity enabled by advanced automated manufacturing.

With decades of expertise, we offer a comprehensive product portfolio of high and low voltage solutions, intercell connect boards (ICB), busbars, extensive eyelet and engineered components, and more. Our E-Catalog includes an easy-to-use part number search and other features to help you find the products you need.
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Connection Systems E-Catalog

High-Voltage Battery Connection Systems

Providing connections between battery cells, from the battery pack to the vehicle’s electrical architecture, and/or between other electrical components within the high-voltage battery pack, our high-voltage battery connection systems provide safe and efficient electric vehicle (EV) performance.

More than three million EVs are expected to rely on Lear’s high-voltage connection systems as the main battery-to-vehicle interface by 2030.

Engineered Components

Our vertically integrated solutions include custom-molded components designed to protect, route, seal and cover wire harness assemblies to ensure outstanding quality and performance.

Electronic Solutions

Our electronic solutions manage electrical power and data throughout the vehicle. As a world leader in electrical distribution systems, we deliver solutions at every level — from full-service design to build-to-print and systems integration.

High-Voltage Power Distribution

Lear’s 15+ years of experience in controlling the flow and distribution of high-voltage power throughout EVs is complemented by our expertise in power and thermal management as well as electrical architecture integration.

Battery Disconnect Unit (BDU)
Lear’s Automotive News PACE Award winning BDU with Flat Flex Wire provides the power and performance large SUVs and trucks require, with 20% less weight, 32% smaller size, and a 135% gain in power transfer compared with traditional offerings.

Low-Voltage Power Distribution

Lear's power distribution systems include both smart and passive solutions. Smart power distribution modules integrate power distribution units with electronic controls into one optimized module for reduced mass and fewer parts. Our hardware includes integrated software to manage increasingly complex and sophisticated electronic architectures.

Controllers

Lear’s zonal and body domain controllers simplify vehicle architecture with intelligent, secure power and data management. Our advanced I/O models enable flexible designs and software-defined functionality. We deliver integrated electronic controllers and low-voltage distribution units with embedded software for precise, reliable communication across vehicle networks.

Zone Control Module
Lear's advanced zone control module (ZCM), which helps enable zonal architectures, earned a 2025 Automotive News PACE Award for its algorithmic circuit protection innovation.

Operational Excellence

Our extensive electronics expertise in complete electrical distribution and connection systems enables Lear to engage with customers early to develop innovative, efficient designs.

An industry-leading suite of in-house developed tools and processes significantly reduce design, development and validation testing time and cost

Proprietary manufacturing processes driven by enhanced digitalization and automation

IDEA by Lear is our call to action to think differently, move quickly, take ownership, and secure our future as a leader in the new era of automotive innovation. This initiative reflects our commitment to leading in a world increasingly defined by advanced, digital, and automated solutions. The four pillars of IDEA—Innovative, Digital, Engineered, and Automated—represent an interconnected framework that drives our operations forward

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