Image Credentials: Image Title: BMW and Ferrari Follow Tesla’s Lead as Aluminum Reshapes the Future of Electric Vehicles. Source: (chatgpt.com) Date: June 2026. Attribution: This image was created using AI-generated imagery (chatgpt.com) by Open Chronicle and does not depict a real-world scene.
By Open Chronicle
A quiet but significant transformation is taking place inside the world’s most advanced electric vehicles. For more than two centuries, copper has been the undisputed standard for electrical wiring, motors, and power systems thanks to its excellent conductivity and reliability. Now, however, rising costs are prompting automakers to replace it with aluminum, a move that could reduce vehicle weight and lower production costs.
The shift comes as copper prices continue to climb. Earlier this year, copper briefly approached a record $15,000 per metric ton, making it one of the most expensive industrial metals used in vehicle production.
By comparison, aluminum currently trades at around $3,100 per metric ton, less than one quarter of copper’s price. This growing price gap is encouraging manufacturers to rethink decades of engineering practice.
Ferrari and BMW expand aluminum use
Ferrari has long relied on aluminum for body panels, engines, and chassis, but the Italian manufacturer is now extending its use to electrical wiring.
The company’s plug-in hybrid 296 already incorporates aluminum wiring, while the newly introduced Luce, Ferrari’s first fully electric vehicle, also adopts the lighter material.
According to Ferrari, the change reduces the weight of the wiring harness by as much as 20 percent, contributing to overall vehicle efficiency.
Ferrari communications executive Dario Esposito emphasized that performance, rather than cost, drove the decision.
“We are not choosing aluminum because it is cheaper. We choose the material that delivers the best performance,” he said.
Nevertheless, the lower production cost represents a welcome additional benefit.
BMW began introducing aluminum conductors as early as 2011 with the 1 Series and has steadily expanded their use since then. Today, the German automaker’s latest eDrive technology employs aluminum conductors in both high- and low-voltage electrical systems.
Industry sources have also suggested that Stellantis has started adopting aluminum wiring, although the company has not officially confirmed the reports.
Tesla and China lead the transition
Among major automakers, Tesla is widely regarded as one of the pioneers of aluminum electrical wiring.
The company began integrating aluminum cabling into the Model Y in 2019 before extending the technology to the Cybertruck.
China, meanwhile, has embraced the transition on a much broader scale.
In March 2025, the Chinese government formally encouraged manufacturers to replace copper with aluminum wherever practical. Automakers including Xpeng, Xiaomi, and AVATR have responded by accelerating the use of aluminum components in their electric vehicles.
For Chinese manufacturers, lighter wiring contributes to greater driving range, while lower material costs help preserve profit margins during an increasingly competitive price war.
Not without challenges
Despite its advantages, aluminum is not a perfect substitute.
Because it conducts electricity less efficiently than copper, thicker cables are required to achieve similar electrical performance.
Aluminum production is also more energy intensive, raising environmental concerns related to manufacturing emissions.
International trade policies may further complicate the transition, particularly in markets such as the United States, where tariffs affect aluminum imports.
Even so, significant room for growth remains.
According to Norwegian aluminum producer Hydro, approximately 85 percent of the busbars that connect electric vehicle batteries to their electrical systems are still made from copper.
A growing industry trend
Analysts expect aluminum to play an increasingly important role across several industries over the coming years.
Investment bank JPMorgan estimates that aluminum could replace around 2 percent of global copper demand this year, rising to approximately 6 percent by 2030.
Chinese consultancy Zhuochuang projects that between 25 and 30 percent of components currently manufactured from copper across the automotive, energy, and household appliance sectors could transition to aluminum before the end of the decade.
As electric vehicles continue to evolve, manufacturers appear increasingly willing to balance material performance with affordability. The growing adoption of aluminum suggests that future electric cars may become lighter, more efficient, and less expensive to produce, even if copper continues to play a vital role in the industry’s most demanding electrical applications.
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Staff Writers at Open Chronicle produce in-depth, field-informed reporting on defense, diplomacy, cultural transformation, and global affairs. Known for clarity, accuracy, and analytical depth, they connect breaking developments to broader historical and strategic contexts. In addition to frontline journalism, Staff Writers also contribute to the Open Chronicle Encyclopedia, crafting authoritative entries that preserve critical knowledge and enrich public understanding.