Introduction
In modern vehicle development, areas around the wheel arch and front hood belong to the most demanding packaging zones. Limited space, exposure to environmental factors and the need to support multiple equipment variants all put strong constraints on wiring and mounting concepts.
In this project, carried out for a premium automotive manufacturer, we were asked to develop a robust mounting concept for splice connections in this tightly packaged area – one that would work across different vehicle configurations without changes to the existing geometry.
Work scope
At the initial stage, the work involved adapting existing wiring harnesses from a previous project and integrating them into the 3D vehicle environment, forming the basis for the development of a dedicated routing and mounting concept.
Our work focused on the development of a stable and repeatable mounting solution for splice connections located in the wheel arch and front hood area.
The scope included:
- Development of plastic brackets to secure splices in defined vehicle zones
- Design of a mounting concept supporting multiple equipment variants within one solution
- Ensuring reliable harness packaging under tight space constraints
- Alignment with existing vehicle geometry, without introducing new holes or modifications in critical areas
- Optimization of fixation features to improve assembly stability and repeatability
- Integration of the traction harness with the electric air conditioning compressor (EKK) harness via a dedicated coupling point mounted on an additional, purpose-designed bracket in the wheel arch area
Throughout the project, particular attention was paid to scalability – the concept had to remain adaptable for future model updates.
Results
The developed solution delivered clear benefits both for assembly and long-term use:
- Improved reliability through stable and secure splice mounting
- Assembly flexibility, with one concept covering multiple equipment variants
- Better packaging and efficient use of limited space in the wheel arch and hood area
- A scalable design that can be easily adapted to future vehicle models
The concept proved robust while remaining fully compatible with the existing vehicle architecture.
Summary
This case shows how careful mechanical and wiring integration can solve complex packaging challenges without increasing system complexity. By focusing on repeatability, stability and variant compatibility, we delivered a mounting concept that supports current production needs while remaining ready for future vehicle generations.
It is a good example of how experience from automotive wiring systems and component design translates into practical, production-oriented solutions.