48V Low-voltage Power Distribution Network (PDN) Architecture and Supply Chain Panorama Research Report, 2026
Research on 48V Low-Voltage Power Distribution Network (PDN): An Active 48V Supply Chain, with Priority Deployment in High-Power Scenarios Such as Steer-by-Wire Chassis
The automotive 48V low-voltage power distribution network (PDN) refers to the entire power transmission and distribution system that uses 48V as the low-voltage distribution standard, covering the path from the power source to the loads. The introduction of a 48V low-voltage electrical system involves key products and technologies such as architectural pathways, 48V power systems, 48V zonal controllers and key chips, 48V motors and actuators, as well as 48V connectors and wiring harnesses.
For a long time, 48V systems have primarily been used in mild hybrid vehicles to improve fuel economy. However, with the rapid development of vehicle intelligence and advanced autonomous driving in new energy vehicles, electrical loads have continued to increase and power demands have grown significantly. Considering factors such as wiring harness complexity, cost, and power consumption, automakers have begun to reassess the value of 48V within the vehicle's E/E architecture. "Tesla Cybertruck","Battery electric pickup truck by Tesla was the first mass-produced vehicle to adopt a 48V low-voltage electrical system, representing a major improvement and simplification of electrical architecture. The 48V PDN is becoming a foundational infrastructure element for next-generation high-end battery electric platforms. Therefore, this report focuses on analyzing the application scenarios of 48V systems in pure electric vehicle platforms and studying the development of the corresponding supply chain.
48V PDN Priority Deployment Scenario 1: 48V Brake-by-Wire Chassis
Based on the current solutions and implementation progress of OEMs and suppliers, the brake-by-wire chassis is the highest-priority deployment scenario for 48V systems in battery electric vehicles. Traditional 12V systems, constrained by power limitations, heavy wiring harnesses, and high energy consumption, struggle to support high-power intelligent loads such as steer-by-wire, brake-by-wire, and fully active suspension systems. The 48V system naturally addresses these challenges.
48V Brake-by-Wire System: A 48V system can provide instantaneous high power of 1–3 kW, meeting the power requirements of EMB motors. It enables faster motor response (with response times reduced to under 100 ms), higher braking precision, and greater braking force, resulting in shorter braking distances. It also supports advanced intelligent driving functions such as Automatic Emergency Braking Systems (AEBS) and emergency autonomous pull-over maneuvers.
Taking Xiaomi Auto's 48V four-wheel dry electromechanical braking system as an example: each wheel is equipped with an independent 48V EMB electronic brake caliper. The motor power module mounted on the caliper directly drives the piston through a mechanical transmission mechanism to generate braking force, achieving higher transmission efficiency and faster braking response. Compared with electro-hydraulic braking systems, the clamping response speed is improved by 40%. In 100 km/h braking tests, the braking distance—from the moment the driver presses the brake pedal to the vehicle coming to a complete stop—is reduced by more than 1 meter.
Xiaomi's 48V brake-by-wire system uses "dual-piston EMB electronic brake calipers." Compared with traditional single-piston EMB calipers, the friction area is increased by 50%, enabling stable and outstanding braking performance even during aggressive driving and repeated braking scenarios. In addition, the high-precision clamping force sensing module doubles clamping accuracy, allowing finer brake control and ensuring smoother deceleration and more precise following distances during braking, greatly enhancing both human-driven and intelligent driving braking experiences. At the same time, Xiaomi's EMB electronic brake calipers feature active caliper-pad gap adjustment, which can intelligently adapt according to operating conditions. This reduces braking system friction losses (drag torque) by 50% and increases vehicle driving range by more than 10 kilometers.
48V steer-by-wire system: The steer-by-wire system adopts a 48V architecture. Its high power density makes a "gearless" direct-drive steer-by-wire system possible, achieving decoupling between the steering wheel and the wheels, supporting steering-wheel-free cabin layouts, and meeting the requirements of advanced autonomous driving for rapid response and fully redundant safety (ASIL-D). In addition, the 48V system enables a lighter and more cost-effective redundant design for steering actuators and allows for an extremely wide steering ratio adjustment range.
Taking Bosch Huayu's 48V direct-drive steer-by-wire product as an example: it adopts a 48V architecture that reduces current and thermal management pressure while satisfying the demand for high steering assist output. In scenarios requiring high power output, such as emergency obstacle avoidance and automated parking, the advantages of the 48V architecture on steering performance become even more apparent. Drivers can directly perceive the improved steering response speed resulting from higher motor speed. Bosch Huayu's 48V steer-by-wire product is expected to enter mass production as early as 2027.
Bosch's 48V direct-drive steer-by-wire steering feel simulation unit adopts a direct-drive solution without a reduction mechanism, enabling lossless transmission of commands. Paired with a 48V electronic control unit, it achieves lightweight design and energy-saving goals. Compared with traditional worm-gear solutions, it improves steering-column rigidity and enhances steering control precision. It not only optimizes NVH performance and steering feel, but also significantly increases power density, delivering more than a 50% increase in assist performance within the same volume. In addition, the simplified product structure and more refined manufacturing processes effectively improve system stability and reliability.
When combined with a large-angle rear-wheel steering system, the 48V direct-drive steer-by-wire technology can deliver a maximum output torque of 15.5 Nm. Its highly integrated structural design greatly improves system rigidity and stability, enabling precise torque output unaffected by temperature fluctuations and providing users with a pure and refined steering feel.
48V Full Active Suspension: The core design philosophy of the 48V full active suspension is to “place the actuator closer to the source of vibration.” It fully integrates and encapsulates the brushless DC motor, miniature hydraulic pump, solenoid valve, and controller within the damper body itself, positioning them directly beside each wheel’s damper. This completely eliminates the central hydraulic pump station and long high-pressure pipelines used in traditional hydraulic suspensions, enabling active adjustments at the millisecond level. The 48V motor drives the active suspension, providing a faster response than conventional hydraulic systems and allowing precise body attitude control for improved handling and ride comfort.
Taking NIO’s 48V integrated full active suspension solution as an example: its core component is a 48V electro-hydraulic pump that highly integrates a micro motor, motor controller, and hydraulic pump body adjacent to the damper. Each wheel is equipped with one electro-hydraulic pump powered by a 48V low-voltage supply. The micro motor uses a 48V BLDC brushless motor with a peak power output of 5 kW. By applying active force to the damper, it adjusts vehicle body attitude. The system can perform 1,000 torque adjustments per second with an adjustment range of up to 90 mm. Its adjustment speed is 60 times faster than that of air suspension systems. In certain scenarios, it can also achieve a degree of regenerative braking energy recovery.
The key advantages of the 48V integrated solution are its rapid response (1 ms actuator response time and a system-level control frequency of 40 Hz) and high precision. Its ability to filter fine vibrations in the 4–8 Hz range, to which the human body is most sensitive, is more than three times better than that of traditional air suspension systems. This makes it particularly suitable for handling everyday road irregularities such as subsidence, bumps, speed humps, and continuous small undulations.
Taking the Zeekr 9X's 48V active suspension solution as an example: its core technology is mainly embodied in its 48V active anti-roll bar. The Zeekr 9X adopts a technical combination of a closed dual-chamber air suspension, dual-valve CCD electromagnetic dampers, and a 48V active anti-roll bar. The 48V active anti-roll bar can instantly correct vehicle body posture, significantly suppress body roll, improve ride comfort on rough roads, and provide side-impact protection. When the vehicle corners at a high speed of 80 km/h, body roll is almost zero.
The micro motor operates on 48V, with a response time of 0.2 seconds. It can provide 1,400 N·m of lifting torque and achieve a maximum lifting effect of 80 mm, allowing the vehicle to maintain near-zero body roll during high-speed cornering. In addition, when an impending side collision is detected, the chassis on the impacted side can be raised instantly within 0.7 seconds.
48V PDN Priority Deployment Scenario 2: 48V Zonal Power Distribution
Current vehicles are designed based on 12V systems. A large number of traditional in-vehicle loads, such as body control modules, lighting, instrument clusters, multimedia systems, windshield wipers, and others, still rely on 12V power supply. Meanwhile, the primary application scenarios for 48V systems target localized high-power devices, including brake-by-wire and steer-by-wire chassis systems, high-power audio systems, intelligent lighting, smart seats, and power window motors. By retaining the main 12V power distribution while introducing localized 48V systems, vehicle performance can be improved. As a result, 12V and 48V systems will coexist in vehicles for a long time. Considering that automakers follow different architectural development paths, 48V power supply will be implemented gradually through transitional stages.
Phase 1: 48V as a third voltage domain added to the 12V system. Current production 48V solutions generally aim to minimize modification costs. A 48V power source and an HV-to-48V DC/DC converter are added to the existing 12V low-voltage power architecture. The primary power distribution levels for both 12V and 48V coexist, with 48V supplying only localized high-power loads. This hybrid power architecture results in the highest complexity for the vehicle wiring harness and power distribution network.
Phase 2: 48V main power distribution with mixed 48V/12V power within zones. This is an intermediate stage in the transition from 12V to a fully 48V architecture. The vehicle’s main power distribution network is upgraded to 48V, and high-power loads have migrated to the 48V system. Some low-power ECUs and loads temporarily remain on the 12V system and are powered through 48V-to-12V DC-DC modules integrated within zonal control units (ZCUs), forming a hybrid architecture in which 48V and 12V coexist within each zone. The core value of this stage lies in reducing system complexity while maintaining compatibility with traditional components that have not yet been adapted to 48V, making it a compromise solution that balances cost and technological evolution.
Phase 3: Full-vehicle 48V power supply. All ECUs and loads are upgraded to 48V, and the vehicle no longer contains any 12V power supply. The system architecture is greatly simplified, achieving optimal performance in terms of cost, weight, and reliability.
With the evolution of automotive E/E architectures, zonal architectures combined with 48V adaptation enable distributed power distribution. The application of 48V systems within zonal controllers mainly revolves around a hybrid power distribution architecture consisting of a “48V backbone network plus localized 12V.” A 48V backbone connects to each zonal controller, where integrated 48V-to-12V DC-DC modules enable mixed power supply for both 48V and 12V loads, providing more flexible power distribution and fault isolation. In zonal power supply scenarios, a 48V architecture can reduce wiring harness weight and cost by approximately 85% compared with a 12V architecture. Even for localized loads such as window motors, more than 60% wiring harness weight reduction and over 50% cost optimization can be achieved.
In April 2026, NXP and Neusoft Reach jointly released the CoreRide Z248 zonal controller system solution based on NeuSAR OS. The solution integrates chips, intelligent power management, pre-integrated safety-certified software, data management, and audio functions. It is expected to launch the Z248 CoreRide B-sample product in the fourth quarter of this year, with the final fully performance-optimized version scheduled for release by the end of 2027.
The CoreRide Z248 zonal controller system solution is NXP’s latest system-level solution for 48V electrical architectures and is developed based on the NXP S32K5 chip platform. The S32K5 features Arm? Cortex?-M7 and Cortex-R52 cores and supports single-core, multicore, or lockstep core configurations. It is manufactured using a 16nm process, adopts MRAM storage technology, and provides functional safety up to ASIL-D.
The Z248 also comes pre-integrated with Neusoft Reach's NeuSAR OS basic software, achieving system-level hardware-software co-optimization. It can be directly used as a foundational platform for OEMs and Tier 1 suppliers to develop zone controllers, reducing zone controller development workload by up to 50%.
48V PDN Industry Chain: Semiconductor Device Maturity Is Relatively High, While the Micromotor Ecosystem Still Needs Improvement
Upgrading from a 12V system to a 48V system also changes the performance requirements for related semiconductor components. Power conversion, driver, and communication chips at the hardware level need to be upgraded, while internal 48V/12V DC-DC converters must be added, along with considerations for voltage isolation and thermal design. In terms of industry chain maturity, products for power management in 48V systems—including e-Fuses, DC/DC converters, high-side switches, gate drivers, bridge driver chips, brushless motor driver chips, brushed motor driver chips, and MOSFETs—are already available. However, because large-scale deployment has not yet occurred, costs remain relatively high. High-integration products such as PMICs and SBC chips are still lacking. Therefore, 48V DC/DC converters are currently the core components of power management in 48V systems.
The transition from 12V to 48V systems also has a significant impact on actuators. Traditional 12V motors, relays, and similar components cannot be directly used in a 48V environment and require redesigned insulation ratings and voltage withstand capabilities. In addition, the copper wire diameter in the rotor windings of 48V motors becomes smaller, the number of turns increases, and the voltage withstand requirements for commutators and brushes rise, requiring adjustments to the winding turns as well. From the perspective of industry chain maturity, actuators and load products such as 48V motors remain relatively immature, and their compatibility with PMICs still needs optimization.
The 48V PDN industry chain is characterized by advanced semiconductor development, lagging actuator development, and standards that are still evolving. With promotion from automakers such as Tesla, NIO, and Xiaomi, as well as the gradual improvement of ISO, SAE, and GB standards, large-scale adoption is expected to reach an inflection point between 2028 and 2030.
To support the next generation of 48V intelligent automotive actuators, Bosch launched the highly integrated SD148 intelligent motor controller in June 2026, specifically designed for native 48V automotive applications. The SD148 integrates multiple key functional modules—including the MCU, PMU, gate driver, current sensing, and communication interfaces—into a single chip, reducing dependence on external components. It offers advantages such as simplified system architecture, fewer external components, lower bill-of-materials costs, improved efficiency, and reduced PCB complexity, optimizing BLDC motor control applications.
The SD148 is powered directly from a 48V vehicle electrical network and supports loads of up to 2 kW. It incorporates a 32-bit ARM? Cortex-M33? processor operating at 80 MHz and supports advanced motor control algorithms such as field-oriented control (FOC). It can be widely used in applications including water pumps, fans, seat adjusters, braking systems, steering systems, and other areas.
The SD148 integrates a high-efficiency switching regulator optimized for automotive 48V systems. Compared with traditional linear voltage conversion methods, it achieves lower power consumption, reduced thermal stress, improved system efficiency, and simplified thermal management. These advantages are particularly evident in medium-power motor applications such as fans and water pumps. The SD148 is specifically designed for next-generation zonal centralized electrical/electronic architectures, supporting the integration of intelligence, sensing, and actuation within compact edge nodes. It enables distributed intelligent actuator architectures while also supporting the evolution toward centralized computing architectures.
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