The decline of copper usage in EVs: A shifting trend in material needs

Copper in electric vehicles: Why it’s declining

Copper is crucial to electric vehicles. It’s used in wiring, motors, charging cables, and other systems that make an EV function. However, the amount of copper per vehicle—often called “copper intensity”—has decreased significantly over the last decade. In 2015, each EV used about 99 kg of copper, but by 2030, that number is expected to fall to just 62 kg. This represents a drop of over 37%, and the reasons for this decline are varied.

One major factor behind the reduction is a strategy known as “thrifting.” This approach focuses on improving the efficiency of vehicle components while reducing the amount of material needed. A good example of this is in battery production, particularly in the copper foil used for battery anodes. Back in 2015, copper foil made up over 41 kg of an EV, but manufacturers have gradually moved towards thinner foils. By 2030, it’s projected that only about 26 kg will be needed.

Additionally, the wiring systems in electric vehicles have been optimised to use less copper. Advances in high-voltage wiring and a more modular approach have allowed manufacturers to cut down on copper usage. What once took 30 kg of copper for wiring in 2015 is expected to drop to 17 kg by 2030. This reduction is the result of better technology, including new methods for managing heat and more compact power electronics.

The rise of aluminum and other alternatives

Copper isn’t just being reduced; it’s also being replaced. In several components, aluminum has become a popular substitute for copper. It’s being used in busbars, wiring harnesses, and charging cables—areas where lighter weight and lower costs are highly beneficial. Aluminum offers some clear advantages: it’s cheaper and weighs less. However, it requires more space to achieve the same level of conductivity, which can sometimes limit where and how it can be used.

Benchmark Mineral Intelligence data indicates that copper use in automotive wiring harnesses has dropped by around 30% between 2015 and 2024, largely due to this shift toward aluminum.

Trends in copper usage across EV components

The decline in copper usage in EVs has been consistent across many of the core parts of electric vehicles:

• Wiring: Dropped from 30 kg per vehicle in 2015 to an estimated 17 kg by 2030.
• Motor: This has remained mostly steady, hovering around 7-8 kg per vehicle.
• Copper Foil: Reduced significantly, from 41 kg in 2015 to a projected 25 kg by 2030.
• Busbar: Expected to drop from 13 kg to just over 5 kg during the same period.
• Auxiliary Motor and Charging Cables: Also saw declines, though the changes have been more modest compared to other components.

Copper demand in the growing EV market

Even though less copper is being used per vehicle, the overall demand for copper from the EV market continues to rise. This is due to the rapid growth in the number of electric vehicles being produced and sold. In 2015, the global EV sector needed about 56.000 tonnes of copper, and by 2030, that demand is expected to reach over 2,5 million tonnes.

This rise in demand shows that electric vehicles will continue to be a major driver of copper consumption, despite the industry’s best efforts to use less copper per car. The rapid growth of electric vehicle adoption is fueling copper’s ongoing importance, keeping it central to the transition towards a low-carbon future.

Broader trends in copper production

While the automotive industry has been reducing its reliance on copper, production of the metal itself has increased, particularly in China. Chinese copper production rose from 1,2 million tonnes in 2010 to 3,7 million tonnes in 2022. By contrast, other major producers, like Codelco, Freeport-McMoRan, and BHP, have seen their combined production grow more slowly—from 3,8 million tonnes in 2010 to 4 million tonnes in 2022.

These shifts in copper production capacity reflect changing dynamics in the market. While efficiency gains are reducing copper intensity in individual vehicles, countries like China are stepping up their production to meet the needs of expanding industries, including EVs.

What lies ahead for copper and EVs

The future of copper in electric vehicles is a mixed story. On the one hand, manufacturers are working hard to reduce how much copper goes into each car, driven by technological advances, cost considerations, and the push to find more efficient solutions. On the other hand, the sheer growth of the electric vehicle market means that total copper demand is set to increase significantly.

Even with aluminum and other alternatives stepping in, copper remains essential. It plays a key role in electrification, helping power everything from the motor to the charging systems. As the world continues to move towards cleaner energy and low-emission vehicles, copper will be a critical material in making that vision a reality.

This decline in copper intensity demonstrates how the EV industry is evolving—becoming more efficient, cost-effective, and increasingly innovative. Yet, despite using less copper per vehicle, the expanding global EV fleet means copper’s place in the low-carbon transition is secure. It’s a balancing act: achieving greater efficiency without losing sight of the need for growth and sustainability.

Source: Visual Capitalist