Spanish Researchers Develop New Material That Could Transform EVs

Spanish researchers have developed a new material that could replace copper wire in electric vehicles (EVs), drones, and aircraft after achieving a 17-fold increase in carbon nanotube conductivity. The breakthrough, published in Science, comes from the Institute of Nanoscience and Materials of Aragon and the IMDEA Materials Institute, and centers on a chemical doping process that significantly enhances electrical performance while preserving structural integrity.

At ambient temperature, the doped fibers reach about 40% of copper's electrical conductivity. On a weight-adjusted basis, their specific conductivity exceeds aluminum, and the fibers weigh roughly one-sixth of copper while offering five times the tensile strength. Earlier versions were tough and lightweight but lacked current-carrying capacity, making this conductivity gain the key development.

The improvement came from treating the fibers with AlCl4-, a tetrachloroaluminate compound that acts as a dopant. Introducing charge carriers without disrupting the atomic lattice had long been a core challenge, and the researchers say this method addresses it. Preserving structural integrity was as important as the conductivity gain, since a conductor that breaks down in service has no practical value.

Modern EVs carry a significant copper load, especially in thick wiring bundles managing high-voltage power, and that mass adds up. Switching part of that copper for a lighter material reduces vehicle weight and extends range, while lower resistivity at operating temperatures cuts heat buildup. In drones, reducing cable mass translates directly into longer flight time, and for aircraft developers, trimming weight at any point yields outsized returns.

The material also holds up reliably in dry conditions and shows acceptable moisture tolerance, properties that matter for transportation certification standards. On specific conductivity, the benchmark manufacturers prioritize most, the treated fibers have entered territory that warrants serious engineering attention. At peak values, they also exceed aluminum's conductivity on an absolute basis.

The remaining challenge is manufacturing: producing consistent fibers at scale, ensuring hardware compatibility, and establishing a cost profile competitive with conventional metals. If those problems can be worked through, the technology could move out of laboratories into the electrical systems of next-generation EVs and aircraft. Recycling infrastructure for these materials will also need to be developed. Many firms in the automotive space, such as Ferrari N.V. (NYSE: RACE), will be watching to see whether this new material becomes commercially available at scale and at price points that make the switch from copper economically viable.