Liquid Cooled EV Charging Cable Market

The 500–900 kW segment is projected to be the largest market during the forecast period. Cables with this capacity range align with most installations of ultrafast DC chargers, which require liquid cooling designs for effective thermal management. This range is becoming the standard for passenger electric vehicles (EVs), buses, and light commercial vehicles, facilitating charger standardization and high asset utilization. Demand for these cables is further driven by the rapid deployment of ultrafast chargers, the increasing adoption of high-voltage vehicle platforms, the growth of fleet and corridor charging, and a better cost-to-performance balance compared to megawatt systems.

The ultrafast charging segment is expected to dominate the liquid cooled EV charging cable market in 2025. This growth is due to its direct service to the high-volume passenger and light commercial electric vehicle (EV) market, which leads global EV deployment. The rapid expansion of public and semi-public charging infrastructure along highways and urban corridors is driving the large-scale installation of chargers with a capacity of 350 kW and above, resulting in a sustained demand for liquid-cooled cables. Furthermore, the increasing adoption of 800 V passenger EV platforms reinforces this trend, as liquid-cooled cables are necessary to safely support higher current operations at scale.

The 5–8 meters segment is projected to lead the liquid cooled EV charging cable market during the forecast period due to its optimal balance of electrical efficiency, thermal performance, and cost. This length minimizes voltage drop and coolant pressure loss during high-current charging, while avoiding the additional material and handling complexities associated with longer cables. It also allows for flexible routing in standard public charging layouts without the need for extra joints, which reduces installation time and lowers reliability risks. Consequently, charger manufacturers and operators are standardizing the 5 to 8 meters as the most practical length for large-scale public fast charging deployments.

The 30–50 mm segment is projected to lead the market during the forecast period. Cables in this diameter range balance power-handling capability, thermal performance, flexibility, and ease of installation for ultrafast and megawatt-class DC charging systems. This diameter range supports the high current transmission needed for chargers of 350 kW and above while keeping the cable weight and bending radius manageable. Additionally, liquid cooling remains efficient within this range, allowing heat to be effectively removed without complicating hose design or increasing coolant flow resistance.

The thermoplastic elastomer segment is expected to lead the market in 2025 due to its flexibility, durability, and resistance to high temperatures and chemicals. This material facilitates easier handling and installation of high-power cables while ensuring effective insulation performance under continuous thermal and mechanical stress. Key driving factors for its adoption include the growing use of ultrafast and megawatt chargers, stringent safety standards that necessitate reliable insulation, and the demand for long-lasting, maintenance-free cables in commercial and public charging infrastructure.

The water glycol segment is projected to lead the market during the forecast period because it effectively dissipates heat at high charging power while ensuring system safety and cost efficiency. Its established use in automotive thermal management ensures reliable performance across diverse climates. Additionally, it provides benefits such as freeze protection and corrosion resistance. Moreover, its compatibility with existing components and well-understood safety standards simplifies integration, accelerates adoption by cable manufacturers, and supports large-scale deployment in public and commercial charging infrastructure.