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Tesla and BMW switch to aluminum from cheaper copper

Ferrari and BMW have introduced new models with lightweight, cost-effective aluminum wiring. This is accelerating the shift away from copper as the dominant material for electric wiring ever since the invention two centuries ago of the electric batteries. JPMorgan predicts that the decisions will affect around 2% global copper demand in this year. Tesla and Chinese EV makers have also made similar moves. The structural increase in copper prices could lead to even more copper being switched over to aluminium. This is due to the increased demand for data centres and green energy, as well as the shortage of copper.

According to 18 interviews conducted with carmakers, cable and AC companies, metals manufacturers, and consultants, many sectors are moving to aluminium due to its lower price and comparable performance. Ferrari and BMW both said that they chose aluminium because it is lighter.

Aluminium has been replacing copper in large waves for the past two decades. However, the record copper prices of late January, which peaked at close to $15,000 a metric ton added to the argument for aluminium. Forecasts for global demand and supply are not in line with each other for the next decade.

LIGHTER and FASTER

Ferrari, who already uses aluminum for its bodies and engines, has said it began using the lightweight metal as?power cables for its 296 hybrid sport car last year. Ferrari has now introduced aluminium wiring to other models including the Luce - its first ever EV, launched last month.

Dario Esposito, Ferrari Communications executive, said that the move could save up to 20 percent of total wiring weight.

He said, "We don't choose aluminium just because it is cheaper. We pick the material with better performance."

The metal is actually much cheaper - currently around $3,100 per ton or about a quarter of the price for copper.

BMW, a German automaker, said that it first began using aluminium conductors for its 1 Series subcompact in 2011, and gradually expanded the use of aluminum in hybrids and electric vehicles. It uses a lot of aluminium cable in the high-voltage and low-voltage system in its eDrive EV, which was launched 'last year. Stellantis - the fourth largest automaker in the world - has also started to replace copper wiring with aluminium recently, according a source familiar with this issue. Stellantis declined comment.

Price versus Performance

Feng Lu, sales director at JONVER, a Chinese supplier of EV parts, has reported that sales of aluminium wire products have risen this year from 20% to 30%.

Norwegian aluminium manufacturer Hydro reported that sales of heating-and air tubing made from aluminium as a substitute for copper have been steadily increasing in recent years. Hydro's CFO Trond Olaf Christophersen stated that the company anticipates gaining market share in future years as aluminium replaces copper.

Xavier Mathieu, a France-based Nexans employee, says that manufacturers will continue to buy copper because it is more efficient in certain applications, but they'll start purchasing aluminium once copper prices are 3.5 times higher.

The price of copper is currently more than four times that of aluminum.

The decision to switch is complicated by several factors, such as the high tariffs in the United States and the enormous amount of energy required to produce aluminum, resulting in more greenhouse gas emission. Aluminium is also cheap, but it's less efficient. It takes more aluminium to conduct a given amount of electricity.

JPMorgan presented a scenario whereby 6% of the annual demand for "copper" could be replaced by aluminum in 2030. This compares to only 2% last year.

CHINA EV MAKERS TAKE THE LEADER

In a policy document dated March 2025, the government of the world's largest metals consumer, China encouraged companies to switch to aluminum. Many have taken the advice.

By 2030, analysts at the consultancy 'Zhuochuang' predict that up to 25% of current copper components in the automotive, home appliance and power sectors could be made out of aluminium.

AVATR, XPeng, and Xiaomi are among the Chinese EV manufacturers that have switched over to aluminium wire, according to Terry Woychowski of engineering consultancy Caresoft Global. The company disassembles vehicles and inspects components.

Tesla and the three Chinese EV manufacturers did not respond when asked for comments.

The lighter weight of?aluminum is particularly attractive to EV manufacturers because it allows for longer driving distances. Saving money is important for EV companies in China where a price war has squeezed margins. Aluminium has plenty of room to grow in the auto industry, where 85% electrical wiring busbars that connect an EV battery to its system are still copper.

Woychowski said that the Chinese auto industry had benchmarked Tesla as a pioneer of using aluminium in wiring, when it launched its Model Y model in 2019 and, more recently, in its Cybertruck. (Reporting from Eric Onstad, Amy Lv, Ju-min Park, Kalea Hall, and Eric Onstad, London; Editing, Veronica Brown, Claudia Parsons).

(source: Reuters)