Aluminium Gains Ground in Electric Vehicle Wiring as Copper Prices Bite

Electric vehicle manufacturers are increasingly turning to aluminium for wiring due to its lighter weight and lower production costs. Luxury brands Ferrari and BMW are at the forefront of this trend, with Ferrari using aluminium in power cables that reduce wiring weight by up to 20%. Meanwhile, BMW has expanded the use of aluminium conductors into high- and low-voltage systems in its eDrive technology.

GEM Mining Consulting notes that while this shift does not signal the end of copper's dominance in electromobility, it is a response to sustained price pressures. The consultancy says manufacturers are looking for areas where aluminium can be used without compromising system performance, as the copper-aluminium price ratio has remained persistently close to or above 3.5 times since 2020.

GEM Mining estimates that material substitution could reduce copper demand by 1.5-6% by 2035, but notes that this should be viewed as optimisation rather than structural displacement. Copper remains the preferred material in applications where electrical efficiency, reliability, and compact design are critical.