The automotive sector has spent decades as one of the world’s largest consumers of wire and cable. A conventional car typically contains between one and two kilometers of wiring. In an electric vehicle (EV), that figure can double. Electrification, therefore, not only increases demand; it reshapes it entirely.
This shift helps explain the heightened technical pressure now facing the cable industry, and the growing role of segments such as cable masterbatch. The International Energy Agency projects that EV sales will account for more than 60% of global total sales before 2035, a figure that makes electrification one of the strongest demand drivers this industry has seen in decades.
One vehicle, thousands of meters of cable: very different requirements
In an EV, not all cables perform the same job or operate under the same conditions. In-cabin cables (used for sensors, controls, and electronic systems) typically work in relatively stable environments. High-voltage cables, however, which connect the battery to the motor or enable fast charging, operate at temperatures that can exceed 150°C.
That difference forces manufacturers to work with highly specialized materials capable of maintaining electrical and mechanical properties over thousands of hours of use. ISO 6722 classifies these cables by thermal resistance, from standard applications up to environments reaching 200°C. Across that range, materials vary from PVC in basic applications, to polyolefins such as PP or PE at intermediate levels, and fluoropolymers such as ETFE or FEP in the most demanding scenarios – precisely the ones gaining relevance as electrification advances.
Masterbatch: when color is also engineering
This is where masterbatch complexity comes into play. Adding color to an automotive cable is not an aesthetic decision. Pigments and additives introduced during extrusion must meet strict requirements, so they do not alter material performance. A poor formulation can affect the cable’s dielectric properties, create instability during production, or trigger failures in the quality controls that validate insulation performance.
In automotive applications, cable color serves a critical function: enabling fast identification of each circuit within increasingly complex systems. Modern vehicles contain hundreds of bundled cables. For assembly and maintenance teams, color provides immediate visual guidance. And in high-voltage systems, a misidentification can have serious consequences.
In this context, Delta Tecnic’s automotive masterbatches ensure color uniformity along the entire length of the cable. In addition, they prevent blooming (pigment migration to the surface under heat) and maintain chromatic stability after thermal aging tests designed to replicate years of real-world operation. These formulations are developed in line with SAE J1128 and ISO 6722 standards and cover thermal classes T2 to T6, including fluoropolymer compounds that are increasingly relevant in high-voltage EV applications.
The challenge of low-dosage systems
The other major vector is dosage. Modern extrusion lines are faster than ever and produce increasingly thin insulation walls, leaving less margin to incorporate masterbatch without affecting compound performance.
To meet this need, high pigment-concentration formulations (high tint strength) are used to achieve the target color at very low addition rates. This helps preserve the compound’s electrical and mechanical properties while optimizing material consumption during production.
In parallel, in the high-temperature segment, ETFE and FEP systems require controlled pigment dispersion to ensure color uniformity and stability during high-temperature extrusion.
These are the same materials used in high-voltage cables, motor circuits, and other mission-critical EV applications.
Charging infrastructure as a new demand hotspot
The rise of EVs is also driving another major front for the cable industry: charging infrastructure. Every charging point – on public streets, in private parking facilities, or at industrial sites, requires medium and low-voltage cabling designed to withstand outdoor conditions, constant UV exposure, and years of intensive use. In some environments, materials must also resist moisture, abrasion, or contact with external agents without compromising performance or safety.
In this context, materials must combine mechanical flexibility with wear resistance and outdoor stability. TPU compounds play that role, while HFFR systems, halogen-free and flame-retardant, address fire safety requirements.
An industry that needs technical partners, not just suppliers
The transition to electric vehicles is redefining what cable manufacturers expect from their masterbatch suppliers. Offering color is no longer enough: suppliers must provide validated color consistency across the cable’s full life cycle, technical support for qualification processes, and the ability to adapt to new polymers.
This level of demand has shifted attention toward players capable of supporting cable technical development end to end: from material formulation to performance under real operating conditions, including thermal aging and dispersion stability.
Ultimately, the growing technical and regulatory demands of the EV segment require every component of the value chain to be rethought. Masterbatch, far from being an accessory, now stands as a critical factor in the safety, durability, and competitiveness of electrical cable.
