Alongside changing how we drive, EVs are reshaping the design of the vehicle cabin. Freed from the constraints of traditional powertrains, EV interiors are transforming into open, versatile and high-tech environments that represent the future of comfort as well as mobility.
However, this design evolution, driven by a simultaneous push for premium comfort and maximum vehicle range, presents complex engineering challenges for securing internal components. This is where advanced fastening solutions become critical enablers for next-generation EV interior design.
As technology advances around EV performance and driving range year on year, the same is going ahead for the design of internal cabin spaces. In the context of comfort, convenience and functionality, there are several key areas that have seen significant development.
The rise of connected features in EVs demands the secure integration of complex sensor arrays, cameras and large touchscreens into the dashboard and console. Many EVs are shifting from physical buttons to all-inclusive screens for control functions, creating a sleek, minimalist aesthetic (though some are making a U-turn back to physical buttons). This uncluttered, sophisticated look requires components to be mounted with high precision and strong vibration resistance.
Reducing vehicle weight is a top priority for improving EV range and efficiency. This mandate extends to the cabin, pushing manufacturers to use advanced lightweight materials like aluminum alloys, high-strength polymers, and composite materials for seats, dashboards, and internal trim. Lightweighting in the interior helps minimise overall vehicle mass.
Designers are committed to creating interiors that offer comfort while being environmentally conscious. This involves integrating sustainable and luxurious materials such as recycled PET plastics, vegan leather, recycled textiles and wood trims.
The shift to lightweight and composite substrates in the EV cabin creates significant fastening problems for engineers:
Wire thread inserts provide the engineering solution that bridges the gap between lightweight materials and robust, repeatable fastening performance. These components create a hardened internal thread that is generally stronger than the original parent material. This works by distributing the mechanical load evenly across all engaged threads, which minimises stress concentration and prevents stripping in soft substrates like aluminum alloys.
Wire thread inserts provide reliable, load-bearing capability for critical structural components and ensure threads remain robust over repeated assembly and disassembly cycles, eliminating the need to scrap expensive lightweight parts due to thread damage. They can be used as a simple and efficient way to repair stripped threads in existing components and also provide ample vibration resistance. For EV interiors, these components are invaluable to help ensure lightweight designs and ensure user comfort, convenience and functionality.The shift in the EV industry towards designing high-performance, aesthetically integrated and lightweight interiors is irreversible. This vision relies on the performance of every single component.
KATO Advanex provides the precision fastening technology (Tanged and Tangless wire thread inserts) that allows engineers to embrace the most advanced lightweight alloys and composites without compromising on the safety, durability or serviceability that define a premium EV experience.
KATO products are used extensively throughout automotive and EV applications, including in the interiors. We are committed to supporting the design and manufacture of the future’s vehicles, where every detail, down to the thread, is engineered for maximum performance. Download our guide below to find out more about the benefits of wire thread inserts in EV designs.