With an estimated value of $2.8 billion in 2024 and a projected annual growth rate of 10.1% through 2034, the global market for off-highway electric vehicles is emerging as one of the most dynamic segments in the industrial energy transition.
Electrification is now a mature and viable solution for construction, agriculture, and industrial logistics—sectors where energy efficiency, emissions reduction, consumption control, and space optimization are critical design requirements. Electric powertrains have become a technically feasible and increasingly competitive alternative to traditional diesel systems. This evolution is largely enabled by the integration of advanced embedded electronics, developed to ensure robustness, operational efficiency, and adaptability to the specific requirements of off-highway vehicles.
Embedded Electronics as the Functional Infrastructure of Electrification
In off-highway vehicles, embedded electronics represent the functional infrastructure enabling full control and management of the vehicle system. These systems handle electric traction, energy conversion, battery monitoring and protection, power supply to auxiliary subsystems, and integration with safety and diagnostic modules.
Standardized solutions are not sufficient in this context. Harsh operating conditions—including shock, dust, thermal cycles, and space constraints—require tailored systems designed around the mechanical and energy architecture of the vehicle.
Power Semiconductor Evolution: SiC and GaN
Wide bandgap (WBG) semiconductors, especially SiC (silicon carbide) and GaN (gallium nitride), play a central role in this transition. These materials enable the development of more compact, efficient, and thermally resilient power conversion systems compared to traditional silicon-based IGBTs or MOSFETs.
Thanks to their ability to operate at higher switching frequencies and temperatures, SiC and GaN allow for a significant reduction in the size and weight of power converters, increasing the vehicle’s power density—a critical factor in off-highway applications where every cubic centimeter and kilogram matters.
The Custom Approach of Prima Electro: From Concept to Validated Product
In this high-complexity technological context, Prima Electro operates as an ODM and system integrator, developing custom embedded architectures for a wide range of off-highway applications, characterized by diverse functional requirements and demanding operational environments.
The company’s integrated development model starts with co-design alongside the customer, taking into account real-world installation constraints, duty cycles, environmental conditions, and applicable regulatory standards. This results in the joint development of tailored hardware and software solutions for electric traction, auxiliary DC/DC conversion, on-board charging, thermal control, and vehicle management systems. Fast validation phases via proof of concept on demonstrator vehicles support the entire development cycle, ensuring a smooth path to industrialization.
This methodology has been successfully applied to several use cases, including high-efficiency traction inverters for electric excavators and construction equipment, compact DC/DC converters optimized for harsh conditions, and on-board charging systems with high power density and modular architectures. Prima Electro has also implemented SiC device integration in electrified agricultural powertrains, improving efficiency and thermal management, and developed digital platforms for remote diagnostics and control, based on CAN networks and standardized industrial protocols.
The Strategic Value of Custom Design
Adopting a custom embedded platform means transforming technical constraints into competitive advantages. Compared to general-purpose solutions, custom electronics:
- enhance overall energy efficiency
- reduce total cost of ownership (TCO) through simplified maintenance
- optimize physical and thermal integration within the vehicle
- ensure full compatibility with automation and fleet management systems
- meet specific regional compliance requirements (EMC, functional safety, interoperability)
The electrification of off-highway vehicles demands systems designed for complex applications and harsh conditions. Only through a system-level and customized approach can efficiency, reliability, and scalability be achieved—effectively supporting the energy transition across the sector.
