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34 SMT007 MAGAZINE I SEPTEMBER 2025 A RT I C L E by S ta nto n Ra k , S F Ra k C o m p a ny The Road to Reliability: Why EV Electronics Matter More Than Ever T he global transition to e-Mobility is redefining the design and reliability expectations of automotive electronics. Unlike their internal combustion engine (ICE) counterparts, EVs operate under "always-on" conditions and are subject to higher voltages, higher currents, and elevated thermal loads. These systems also incorporate exponentially more sensors, control units, and advanced power electronics, often tightly packed in thermally constrained spaces. The proliferation of electronics is driven not only by electrifica- tion but also by customer demand for features like over-the-air (OTA) updates, connectivity, autonomous driving capabilities, and enhanced safety. While these features increase functionality, they also introduce new vectors for failure, especially when software and hardware development are not properly synchronized. In a survey by Molex and Mouser, 67% of industry respondents indicated that software development is prioritized over hardware, underscoring a growing imbalance that could compromise long- term reliability 1 . Additionally, new entrants to the automotive electronics sup- ply chain may not be well-versed in high-reliability design and manufacturing practices for harsh environments. Compounding this challenge is a regulatory landscape still under develop- As EVs race forward as the transforma- tive force in transportation, the reliable workhorses of this transition—the elec- tronics—deserve critical attention. From propulsion to charging, and software to sensors, the reliability of EV electronics is now a key determinant of success. The EV ecosystem is more than batter- ies and motors; it's a complex, interde- pendent network of electronics under stress from heat, voltage, vibration, and rapid innovation cycles. While navigat- ing this electrified path, it's clear that the road to widespread EV adoption must begin with a road to reliability. This article is the first in a series meant to bring attention to the reliabil- ity challenges facing EV electronics components and systems. The articles are based on a comprehensive tech- nical analysis being assembled by the Global Electronics Association.