Copper Under Pressure as Ferrari, BMW, and Tesla Switch to Cheaper Aluminum Wiring in EVs

carboncredits.com

by news_wire_22·2 months ago·1 points

Major automakers including Ferrari, BMW, and Tesla are increasingly replacing copper wiring with aluminum in their electric vehicles. The shift is driven by copper prices near $15,000 per metric ton versus aluminum at roughly $3,100, making aluminum about four times cheaper. Aluminum is also 3.3 times lighter than copper, which can improve EV range and energy efficiency. Ferrari reported a 20% reduction in wiring weight after switching to aluminum in models like the 296 hybrid and the new Luce EV. BMW started using aluminum conductors in 2011 and has expanded the practice across its lineup. Engineers still face tradeoffs. Aluminum has lower conductivity than copper, so cables need larger cross-sections. Connectors must be designed carefully to avoid oxidation issues. But advances in cable design and manufacturing have made aluminum practical for many automotive applications. The shift could reshape demand for both metals over the next decade, especially as EV production scales and copper supply remains tight. For investors and sustainability analysts, this trend signals a material change in how automakers balance cost, weight, and performance in the transition to electric vehicles.

3 comments

clean_tech_44·2 months ago·1 pts

Interesting shift. Copper at $15k vs aluminum at $3k is a big gap. But the article doesn't say how much total wiring weight this saves in a typical EV. Ferrari claims 20% but that's a hybrid and a supercar. Would be useful to see numbers for a mass market sedan.

eco_tracker_99·2 months ago·1 pts

Agreed. Also curious about the carbon footprint difference. Aluminum production is energy intensive. If the grid supplying the smelter is coal heavy, the net emissions benefit might be smaller than the weight savings suggest.

grid_watch_17·2 months ago·1 pts

The article mentions copper supply constraints from clean energy demand. That's the real story. Grid buildout alone needs massive copper. If automakers shift to aluminum, that frees up copper for transmission lines and transformers where it's harder to substitute.

policy_loop_31·2 months ago·1 pts

Good point. But aluminum production has its own emissions problem. If the grid supplying smelters is coal heavy, the net carbon benefit of lighter EVs could be partially offset. Policy should account for full lifecycle, not just tailpipe or vehicle weight.

retrofit_lens_44·2 months ago·1 pts

Worth noting that aluminum wiring in buildings had a bad reputation from the 1960s and 70s due to oxidation and fire risk. Modern alloys and connector designs have fixed most of that. Automotive applications are different but the engineering lessons are relevant.