High Voltage Electric Heaters for Automotive Market Report: forecast to hit US$ 6,272 million by 2031 with 25.2% CAGR

According to the recent report from QYResearch, high-voltage electric heaters (HVEH) are moving into a rapid growth stage as electric platforms and 800-volt architectures become mainstream. The global market size reached US$ 1,324 million in 2024 and is forecast to hit US$ 6,272 million by 2031, representing at 25.2% CAGR between 2025 and 2031. Asia-Pacific leads demand at about 46%, followed by Europe with 36% and North America with 13%. The 4-7 kW category already dominates with 68% share, while BEVs and PHEVs remain the largest application segments.

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Latest Company Developments

BorgWarner secured its largest North American high-voltage coolant heater contract for a 400-V plug-in hybrid platform, delivering power up to 10 kW with thick-film elements and brazed-fin exchangers. The awarded program is scheduled to enter production later in the decade. The company also confirmed new HVCH projects across China, Korea, and Japan, covering 250-800 V and ranging from 3-10 kW.

Webasto introduced three compact models-HVH 100 Compact, HVH 100 Compact+, and HVH 120-delivering 10-12 kW with efficiency above 95% and voltage ranges from 250-880 V. These are designed for cars through heavy vehicles and are being adopted into production lines in 2025.

Eberspächer launched a new high-voltage electrical water heater for electric buses, operating at 500-820 V DC and providing 10 kW per unit, scalable up to 30 kW. The system integrates CAN control and diagnostics, serving growing demand in public transport electrification.

DBK Group expanded its high-voltage coolant heater portfolio with models rated 195-450 V and up to 7 kW. The units achieve around 98% efficiency and now feature LIN control options for precise management.

Woory Corporation continued to scale supply of high-voltage PTC heaters to global OEMs, with solutions supporting both HVAC and battery loop heating on 400-800 V platforms.

Leading Companies

BorgWarner
Webasto Group
HGTECH
Eberspacher
Woory Corporation
DBK Group
Mahle
LG
Mitsubishi Heavy Industries

Applications

HEV
PHEV
BEV

Classification by Power

Up to 4 kW
4-7 kW
Above 7 kW

Latest Data

2024 Market Size: US$ 1,324 million
2031 Forecast: US$ 6,272 million
CAGR (2025-2031): 25.2%
Regional Mix: Asia-Pacific ~46%, Europe ~36%, North America ~13%
By Power: 4-7 kW ~68%, under 4 kW ~22%, above 7 kW remainder
By Application: BEV ~53%, HEV ~38%, PHEV balance

Product Snapshots from Leading Companies

BorgWarner - High Voltage Coolant Heater (HVCH)

· Rated power up to 10 kW

· Voltage compatibility: 250-800 V

· Thick-film heating element and brazed-fin design

· Enables battery conditioning and cabin heating

· Designed for 15,000-hour service life

Webasto - HVH 100 Compact / HVH 120

· Power range 10-12 kW

· Voltage: 250-880 V

· Efficiency above 95%

· Compact dimensions and light weight

· Lifetime heating capacity 15,000-25,000 hours

Eberspächer - High Voltage Electrical Water Heater

· 10 kW per module, scalable to 30 kW

· Voltage: 500-820 V DC

· CAN communication and diagnostic functions

· Used for both cabin heating and battery pre-conditioning

· Optimized for electric buses and commercial EVs

DBK Group - High Voltage Coolant Heater

· Power rating up to 7 kW

· Voltage window 195-450 V

· Efficiency close to 98%

· Compact lightweight construction

· Available with LIN control for advanced integration

Woory Corporation - High-Voltage PTC Heater

· Range covering 400-800 V platforms

· Focused on HVAC and battery loop heating

· Widely adopted by global EV OEMs

· Designed for high safety and durability standards

Downstream Customers

Volkswagen
Ford Motor Company
Hyundai Motor Company
Kia Corporation
Tesla
Rivian
BMW Group
Geely Auto
Škoda Auto
Cupra
Audi
Zeekr

Market Trend

Shift Toward 800-Volt Architectures

Automakers are scaling 800-V platforms to reduce current levels, cable mass, and charging time. Suppliers have responded with heaters supporting up to 880 V. This transition is accelerating in 2025 as high-performance EVs and mass-market platforms alike seek faster charging and improved efficiency.

Heat Pumps and Heaters as Complements

Heat pumps are increasingly common as the primary cabin heating solution. However, high-voltage heaters remain critical for rapid defrosting, extreme cold conditions, and battery pre-conditioning. The combined systems ensure efficiency without compromising winter performance.

Battery Pre-Conditioning as a Core Function

Fast-charging networks demand accurate thermal management. High-voltage heaters are central to pre-conditioning batteries before rapid charging, improving charge acceptance and protecting cell life. The function is now highlighted by major OEMs as essential to consumer experience.

Integration into Thermal Modules

Suppliers are developing integrated thermal modules that combine heaters, pumps, and chillers into compact systems. This reduces weight, cost, and space, while providing better control. Several modules are now designed to handle natural refrigerants and future regulatory standards.

EV Sales Surge Drives Heater Volumes

The global EV market is expected to surpass 20 million unit sales in 2025, following more than 17 million sold in 2024. This sharp rise directly boosts the installed base for high-voltage heaters, especially in BEVs and PHEVs, which require efficient cabin and battery thermal control.

Supply Chain and Trade Adjustments

Tariff policies continue to shape market strategies. The U.S. increased tariffs on Chinese EVs to 100% in 2024, which is pushing heater suppliers to regionalize production and diversify sourcing to reduce exposure. Europe and North America are likely to see localized heater production expand.

Commercial Vehicle Electrification Expands Demand

Electrification of buses and trucks is creating demand for 10-30 kW heating solutions. Modular units capable of high power output are increasingly adopted, particularly in public transit and logistics sectors where winter performance is essential.

Safety and Efficiency as Standard Features

Products are now designed with advanced safety compliance, including functional safety and cybersecurity standards. Efficiency above 95% and lifespans up to 25,000 hours are becoming benchmarks, ensuring that heaters do not significantly compromise EV range or durability.

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