Fluid routing solutions for automotive fastening challenges

The automotive industry is rapidly evolving, driven by electrification, autonomous system electronics, and the need for efficiency. As vehicle architectures evolve, fluid routing management has become mission-critical.

Modern electric and hybrid vehicles need advanced fluid routing solutions (FRS) to manage both flexible and rigid multi-loop coolant circuits and high-pressure lines in theit complex thermal management sytsems (TMS).

Engineers have to integrate multiple fluid systems – coolant, brake, fuel, cleaning and HVAC lines – within dense packaging spaces, while meeting strict safety, sustainability, regulatory, and cost requirements.

Optimal bend radius, minimal noise, vibration, harshness (NVH) and thermal homogeneity are prerequisites for system reliability and occupant comfort. Precise, lightweight and robust fluid fasteners, holders and retainers are essential.

Fluid routing challenges – where we help:

To achieve the right FRS results, automotive OEM and Tier 1 suppliers need a partner with advanced design and material know-how and strong regional production capabilities – like HellermannTyton – to engineer fluid routing solutions that expertly navigate around sensor exclusion zones, crash safety areas, and densely packed electronic components. 

We work collaboratively with our customers' engineers to help them address all their vehicle platform needs with the most efficient, performant and cost-effective fasteners, in all the right places – utilising the wide spectrum of interface possibilities

HellermannTyton's Key Account Manager, Walter Alexander Warnecke, talks about the special challenges of fluid fastening and the increasing engineering complexity for OEMs. 

→ Read the interview here

Order free samples here of the latest HellermannTyton standard parts for fluid routing management

Modular Omega Clips (MOC) are commonly used in fluid systems such as fuel, brake, vacuum, and cleaning fluid lines, as well as in combination with wiring harnesses, HVAC systems, and powertrain thermal management. Use cases also include engine venting, fuel vapor recovery, battery cooling, and air conditioning lines, as well as screen, sensor and camera cleaning fluid hoses. Their modular architecture – with 12 distinct variants – facilitates excellent configuration flexibility. 

The MOC Series combines the benefits of clips and ties and is paired with mounting options including edge clips, fir trees, stud mounts, and extenders for larger offsets – as well as ties and other MOCs and LOCs – providing a comprehensive routing solution.

Engineered to meet the demanding requirements of modern vehicle assembly, our parallel cable holders feature an oval housing for welding studs, enabling tolerance compensation during installation. This ensures a secure and reliable fit, even in tight or complex automotive mounting environments. Thanks to its soft-push design, the part is easy to install without any tools, saving time and enhancing operator comfort during vehicle assembly.

If you prefer a solution with ties, rather than clips or clamps, HellermannTyton also offers a wide range of automotive fixing ties for multiple line fastening on all types of interfaces.

In addition to our specialisation in edge clips for use with cable ties, we also offer a dedicated range of EdgeClips for pipes and hoses of various diameters. These compact edge fixing elements for tubes are simple to push onto an available edge by hand. Once positioned, the integrated clamp closes securely with a distinct, reassuring click, ensuring that pipes and hoses remain firmly in place even under constant vibration or thermal cycling. 

The design supports effortless re-opening whenever required, giving technicians easy access without compromising the attachment point. Thanks to their robustness, corrosion resistance, and versatility across a wide range of edge thicknesses, HellermannTyton EdgeClips provide a highly efficient, cost-effective solution for routing fluid lines in tight or complex installation environments.

Corrugated and convoluted tubing is widely used in automotive fluid routing to shield lines from abrasion, heat, and movement—especially in tight packaging spaces around HVAC, underbody sections, and thermal management loops.

HellermannTyton’s specialised retainer clips and clamps for corrugated tubes secure these protective sleeves without compressing or deforming them, ensuring unrestricted flow and preventing slippage even under vibration and dynamic load.

Designed for fast, tool-free installation and available in multiple interface options, these fastening solutions help engineers route fluid lines safely, cleanly and efficiently across the vehicle architecture.

Key benefits of the ATS flex for the automotive industry:

1. Faster processing: assembly time cut by up to 70% (e.g. 2.4 sec vs. 8 sec manually)

2. Consistent results: automatic calibration and integrated process control

3. Flexible set-ups: integrate into automated production or use bench-mounted or suspended

4. Greater safety: protects hoses from overtightening and operators from strain

5. Material efficiency: the exact tie strap amount is used, reducing waste and disposal costs.

The 2-component Soft Grip Series, made from PA66HS and TPE, is specially designed to secure sensitive bundles like fluid-carrying hoses in automotive applications. This cable tie ensures enhanced protection where it matters most – especially in areas exposed to vibration or movement, where NVH is an issue.

A key feature of the design is a soft TPE inner layer that cushions and stabilises the bundle, preventing lateral movement without compromising the integrity of smooth tubing surfaces. This makes it ideal for use in fluid routing systems, where traditional ties may slip, cause abrasion, or contribute to unwanted noise.

The pre-locking mechanism allows the cable tie to be held in position on the bundle before final tensioning, simplifying assembly processes and improving installation accuracy. Thanks to their soft TPE inner layer, Soft Grip ties ensure a high level of protection with a secure grip that prevents lateral slippage even on smooth tubing.

Interchangeable foot parts make this a versatile off-the-shelf fluid routing fastening solution. The EVO9 SG application tool ensures consistent tensioning and the flush cuts that are essential in automotive assembly.

Order a free Soft Grip Sample Pack and test this unique product in your next project.

Reliable fluid routing ensures consistent coolant flow to prevent overheating or overcooling that can cause efficiency losses or failure.

Effective thermal management is vital for performance, efficiency, safety and component life. In battery electric (BEV) and hybrid electric (HEV) systems, powertrains, regenerative braking and charging generate significant heat, while battery operating temperature must be maintained within a strict range – ideally between 20˚C and 40˚C.

Like in electric vehicle (EV) systems, precise fluid routing in internal combustion engine (ICE) vehicle systems maintains optimal engine temperature, avoiding excess fuel use, oil degradation or component damage. By directing coolant through key areas, well-designed systems enable efficient heat transfer, balance thermal loads and optimise energy use.

HellermannTyton offers proven solutions for both brake and fuel line applications.

Precise routing is critical to maintain consistent hydraulic pressure, minimise heat exposure and prevent vibration-related wear or fatigue of hydraulic lines that carry brake fluid from the master cylinder to the callipers or wheel cylinders.

Releasable Ratchet O-Clamps, featuring soft TPE over moulding, prevent axial slip and support good NVH. This standard part family is related to our long experience producing bespoke brake line fasteners.

Good routing choices prevent kinks, leaks or pressure loss – all of which compromise braking performance and safety.

Fuel line routing plays a vital role in delivering fuel from the tank to the engine and related components. Lines must be positioned to avoid heat sources, sharp bends and vibration-prone areas to prevent vapour lock, leaks or abrasion. Efficient routing also supports compliance with safety and emissions standards while simplifying assembly and maintenance. For complex layouts, Modular Omega Clips (MOC) and Locking Omega Clamps (LOC) deliver near-custom routing without the delays or cost of bespoke designs.

Efficient fluid routing in heating, ventilation and air conditioning (HVAC) systems is essential for reliable thermal transfer and energy performance. 

Optimised HVAC hose fastening can prevent pressure drops, flow imbalance and heat loss, which otherwise impact energy consumption and placing unnecessary strain on compressors, pumps and valves. Refrigerant, coolant and condensate lines must avoid interference with other components, remain accessible for service and withstand extreme temperature ranges without material degradation.

Our solutions are engineered to resist corrosion, vibration and chemical exposure while helping reduce NVH transmission into the cabin. 

Explore how the shift to EV is reshaping the demands of wire and fluid management.

Dive into how HellermannTyton is helping OEMs reduce weight, maximise range and automate with smarter routing solutions.

→ Read the article here