Cables and Wires Make Charging E-Cars Simple and Convenient

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The expansion of the charging infrastructure for electric vehicles is progressing inexorably. The corporate start-up Lapp Mobility GmbH of the Lapp Group supplies accessories for this dynamic market. The two managing directors highlight challenges and opportunities.

In 2023, around 2.3 million electric vehicles were on the roads in Germany. Worldwide, the number is estimated to be about 42 million electric cars, according to the Centre for Solar Energy and Hydrogen Research. Thus, they make up a small but steadily growing share of the more than 1.5 billion motor vehicles. Nevertheless, the situation remains challenging. "And not just in Germany," emphasizes Dr. Simon Alig, who, along with Miro Ivankovich, forms the management of Lapp Mobility GmbH. "The market is very legislation-driven. Additionally, the requirements for manufacturers and suppliers are increasing."

At the same time, many countries are reducing or completely abolishing their government subsidies for electric vehicles. In Germany, for example, the subsidies for electric cars and plug-in hybrids were abruptly cut at the end of 2023. This reduces attractiveness for consumers, particularly in price-sensitive markets. For companies like Lapp Mobility GmbH, this means adapting flexibly to the changing conditions to remain competitive. The market is fiercely contested, and numerous promising start-ups have already been pushed out in recent years.

E-Mobility Indispensable for Energy Transition

E-mobility is indispensable for the urgently needed energy transition. It is considered a central component for a sustainable and climate-friendly transport system based on renewable energies. Norway is already leading the way: around 90 percent of newly registered cars are fully electric there.

Road traffic continues to account for the majority of transport-related CO₂, air pollutant, and noise emissions. Therefore, it is clear that traffic must become more environmentally friendly. According to the Intergovernmental Panel on Climate Change (IPCC), electric vehicles powered by electricity from low-emission sources offer the greatest climate protection potential over their entire lifecycle among all land-based transport technologies. Even with today's electricity mix, their carbon footprint is better than that of all gasoline and diesel vehicles.

However, the transition requires bright minds among infrastructure operators, charging station and vehicle manufacturers, and solution providers. They must rely on the right ideas to continue on the right path in the faltering market.

Lapp Mobility GmbH, a company of the Lapp Group, specializes in the development and production of solutions for electromobility and now offers products for electric car manufacturers, private electric car drivers, charging station manufacturers, infrastructure operators, and other companies active in the e-mobility sector. "Our portfolio includes AC charging solutions such as Mode 3 charging cables for charging at columns and wall boxes, but also Mode 2 solutions suitable for industrial and household sockets, as well as complete solutions for the entire cabling of AC and DC charging infrastructures," summarizes Miro Ivankovic. A particular challenge here: "The technical development in this area is rapid, and the market shares are fiercely contested."

Batteries Becoming Increasingly Cheaper, Charging Increasingly Faster

"How quickly all this has developed can be compared to the evolution of our cell phones and smartphones," explains Simon Alig. "An old Nokia phone seemed primitive to us just a few years later, and the same goes for the batteries of e-vehicles: they are becoming cheaper, and charging is getting faster." This means that it makes a big difference to consumers which vehicle they buy. It is true: a newer vehicle has significantly better charging technology and battery. This also strongly influences consumers' purchasing decisions and thus the market.

Expertise for Custom AC Charging Solutions

Currently, Lapp Mobility GmbH primarily offers AC charging solutions. "Our current portfolio focuses on alternating current (AC) charging solutions with charging capacities of up to 22 kW," describes Miro Ivankovic. "Among the most popular products at the moment is our Mode 3 charging cable with the patented Helix design." Lapp's charging cable allows for easy, independent coiling due to the cable's shape memory. By preventing cumbersome cable tangles, it is especially suitable for carrying in the vehicle itself and for on-the-go charging at charging stations. The corporate start-up has also developed a solution for the conventional Schuko socket: the Mobility Dock with a charging capacity of 2.4 kW, which serves as an emergency charger for the road in combination with a standard Mode 3 cable. Additionally, the range includes two mobile Mode 2 wallboxes, covering flexible charging capacities from 2.4 kW to 22 kW.

"The market has changed here with the end of the KfW wallbox subsidy, so our focus has since been on such flexible AC solutions," explains Simon Alig. The products target both private car drivers and providers of charging infrastructure. "Our unique selling point lies in our expertise and customer service. We develop customized solutions that are precisely tailored to the needs of our partners," says Alig. In this way, the corporate start-up was able to once again win over a large automobile manufacturer for a project on custom development. The specially developed chargers from Lapp will soon be found in all models.

Complete Solutions for Convenient Charging

The charging infrastructure is an increasingly important market for Lapp Mobility GmbH. "This is such an exciting area for us because we inherently possess comprehensive expertise in connection solutions," says Miro Ivankovic. After all, Lapp specializes in all challenges related to connection solutions. "And that is precisely what sets us apart from the competition," Ivankovic continues. "Among our market peers, we are the expert company for cables. By cleverly utilizing our internal synergies, we can work much more flexibly and with far more concentrated expertise than other companies. While we started with charging cables, we quickly realized that we can do much more."

Thus, infrastructure providers can easily integrate components from Lapp Mobility GmbH into existing systems, including standardized components like cables that are also suitable for applications outside of electromobility, such as in packaging systems. For EV ecosystems, Lapp and thus also Lapp Mobility GmbH offer everything necessary to provide complete solutions for the entire cabling of AC and DC charging infrastructures. This includes both the cabling within charging boxes and supply lines for charging stations and parks.

Moreover, Lapp Mobility GmbH leverages internal synergies not only for production but also for the development of new products and solutions, including battery technology. An in-house development team works closely on industry trends and focuses on optimizing and newly developing core products for e-mobility. Soon, a new DC solution will expand the portfolio. The goal is always to combine durable products, optimized handling, sound expertise, and thoughtful design. "Our vision is to make charging e-cars easier and more convenient," explains Simon Alig. "The simpler the overall handling, the more people we can inspire for a sustainable transition."

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