A team of researchers from the Institute of Nanoscience and Materials of Aragon and the IMDEA Materials Institute in Spain has developed a new material that could transform the electrical systems of electric vehicles (EVs), drones, and aircraft. Their findings, published in the journal Science, detail a chemical doping process that boosts the conductivity of carbon nanotube fibers by 17-fold while maintaining their structural integrity. At ambient temperature, the treated fibers achieve about 40% of copper's electrical conductivity, but on a weight-adjusted basis, their specific conductivity exceeds that of aluminum. The fibers weigh roughly one-sixth of copper while offering five times the tensile strength.
The key innovation involves treating the fibers with tetrachloroaluminate (AlCl4-), a compound that acts as a dopant by introducing charge carriers without disrupting the atomic lattice. This has been a longstanding challenge in the field. Preserving the structural integrity is crucial, as a conductor that fails in service has no practical value. The researchers note that this method effectively addresses the difficulty.
The implications for EVs are significant. Modern EVs carry a substantial amount of copper, especially in high-voltage wiring bundles, which adds considerable weight. Replacing part of that copper with a lighter material reduces vehicle mass, extends range, and lowers heat buildup due to reduced resistivity at operating temperatures. In drones, reducing cable mass directly translates to longer flight times, and for aircraft, weight reduction yields outsized returns. The material also performs reliably in dry conditions and shows acceptable moisture tolerance, meeting key requirements for transportation certification standards.
On specific conductivity—a benchmark manufacturers prioritize—the treated fibers have entered territory that warrants serious engineering attention. At peak values, their absolute conductivity exceeds that of aluminum. However, challenges remain in manufacturing: producing consistent fibers at scale, ensuring hardware compatibility, and establishing a cost profile competitive with conventional metals. Recycling infrastructure for these materials will also need to be developed.
Many automotive companies, such as Ferrari N.V. (NYSE: RACE), are closely watching to see whether this new material becomes commercially available at scale and at price points that make the switch from copper economically viable. If these obstacles are overcome, the technology could move from laboratories into the electrical systems of next-generation EVs and aircraft.
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