Let’s discusses the decreasing copper intensity in passenger battery electric vehicles (BEVs) over the past decade, highlighting advancements in technology and the use of alternative materials like aluminum. Based on data from Benchmark Mineral Intelligence, which shows that the copper usage per vehicle is expected to drop from 99 kg in 2015 to 62 kg by 2030, a reduction of nearly 38 kg.
Key factors contributing to this decline include “thrifting,” where engineers enhance component efficiency, resulting in less copper needed—especially in battery production where copper foil thickness is decreasing. For example, copper foil usage is projected to decrease from over 41 kg to 26 kg per vehicle by 2030. Similarly, copper in wiring systems is expected to fall from 30 kg to 17 kg due to improved design and modular integration.
Despite reduced copper usage per vehicle, overall copper demand from the EV sector is anticipated to grow, exceeding 2.5 million tonnes by 2030. It is important to note that aluminum is increasingly being used for specific applications due to its lighter weight and lower cost, though its conductivity limitations can restrict its use. Overall, the analysis underscores copper’s essential role in the transition to a low-carbon future.
