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50 SMT007 MAGAZINE I JULY 2026 Standards Continue to Evolve As EV technology matures, standards need to keep up. Existing standards from organizations such as IPC, IEC, ISO, SAE, UL, and AEC provide important foundations for design, qualification, manufac- turing, and validation. 19-24 Many of these standards originated before the widespread adoption of high- voltage EV architectures. As a result, some qualifi- cation methods do not fully represent the combined stresses experienced by modern EV electronics. Examples include: • Continuous electrical bias over long service periods • High-voltage operation in humid environ- ments • Combined thermal, electrical, and environ- mental stress • Long-duration exposure exceeding traditional qualification periods • High-power cycling conditions associated with fast charging • Outdoor charging infrastructure operating under severe environmental conditions Recognizing these challenges, industry groups have begun developing new guidance and test methods that better reflect current operating conditions. High-voltage temperature-humidity- bias testing, insulation performance assess- ment, contamination control methodologies, and advanced power electronics qualification approaches are receiving increasing attention. 25,26 The objective is for qualification testing to replicate the stresses that products are likely to encounter during actual service. Closing the Gap Between Qualification and Reality One of the recurring themes throughout this series has been the difference between laboratory quali- fication and real-world operation. Laboratory testing remains essential. It provides repeatability, controlled conditions, and a basis for comparison. At the same time, field environments often intro- duce combinations of stressors that are difficult to reproduce completely in any single test. Tempera- ture, humidity, contamination, vibration, voltage, duty cycle, altitude, software updates, charging behavior, and user interaction may all influence long-term reliability. 27,28 This reality argues for a balanced approach that combines: • Robust qualification testing • Accelerated life testing • Field data collection • Fleet monitoring • Failure analysis • Continuous improvement processes Organizations that successfully connect these activities create feedback loops that improve future designs and reduce field risk. Lessons for the Road Ahead The transition to electrified transportation is one of the largest engineering efforts in automotive history. Significant progress has already been achieved. Vehicle range is increasing, charging times are decreasing, and reliability is improving. The lessons emerging from the field are clear: Reliability begins with sound materials selection. It depends on disciplined design practices. It requires robust manufacturing processes. It benefits from continuous monitoring. It improves through data- driven feedback. It is strengthened by standards that reflect real-world operating conditions. Most importantly, reliability is an ongoing engi- neering discipline. Technologies, architectures, and operating environments will change. Engineers, manufacturers, suppliers, standards organizations, and vehicle producers all play a role in the road to reliability. The future of EV reliability will be deter- mined not only by how vehicles are designed, but by how effectively the industry learns from experi- ence and applies those lessons to the next genera- tion of products. SMT007 Dr. Stanton Rak is princi- pal consultant for SF Rak Company, and co-chair of the APEX EXPO Technical Program Committee.