Home> Industry News> The automotive wiring harness industry is witnessing a "aluminum-for-copper" technological revolution, with new materials poised to unlock a market space worth billions.

The automotive wiring harness industry is witnessing a "aluminum-for-copper" technological revolution, with new materials poised to unlock a market space worth billions.

2025,08,25
As the new energy vehicle (NEV) industry experiences rapid growth, a quiet material revolution is unfolding in the Automotive Wiring Harness sector. The long-standing "aluminum-for-copper" technical bottleneck, which has plagued the industry for over two decades, has finally been overcome.
 
In late August 2025, the wiring harness industry saw several technological advancements. Among these, the historic breakthrough in "aluminum-for-copper" technology is particularly noteworthy. This innovation is expected to alleviate China's copper resource shortage and provide a new avenue for companies to reduce costs and improve efficiency.

01Industry Background: Resource Bottlenecks and Cost Pressures
The widespread adoption of new energy vehicles (NEVs) has significantly increased the copper usage per vehicle. A pure electric vehicle (EV) uses over 60 kilograms of copper, which is 3 to 4 times more than a conventional internal combustion engine (ICE) vehicle. As the world's largest NEV market, China faces an annual copper shortage of 800,000 tons, heavily relying on imports, thus posing serious challenges to resource security and supply chain stability. The high cost of copper and the pressure on companies to reduce costs have driven the industry to seek alternative materials. Aluminum, which is only one-third the price of copper, has a lower density and more abundant reserves, making it a promising substitute.

02Technical Breakthrough: Overcoming a 20-Year Challenge
"Aluminum substitution for copper" is not a new concept, but it has not been widely applied over the past 20 years due to two major technical bottlenecks: the creep problem of aluminum materials and the issue of electrochemical corrosion. Aluminum undergoes creep (slow plastic deformation) at high temperatures, which affects the quality and lifespan of vehicles. Electrochemical corrosion, which causes the depletion of aluminum rather than rusting, is an even more critical challenge.
 
Through atomic-level design of aluminum alloy materials, researchers have fundamentally addressed these issues. The new aluminum alloy maintains stable mechanical properties at high temperatures up to 180°C, with creep performance approaching that of pure copper.

03 Economic Benefits and Market Prospects
The economic benefits brought by the "aluminum-for-copper" technology are significant. Upon full-scale promotion, each vehicle can reduce its copper usage by approximately 10 kilograms, leading to a 10% decrease in costs, with noticeable effects on overall vehicle weight reduction. According to estimates, this technology is expected to open up a new market space for low-voltage wire harness materials valued at 36 to 48 billion yuan. Based on the current growth rate of new energy vehicle sales, the penetration rate of aluminum in automotive wire harnesses could reach 65% by 2030.

04Environmental Value: Emission Reduction and Sustainable Development
The smelting of primary copper produces a significant amount of carbon dioxide. Replacing copper with aluminum not only reduces the use of copper but also significantly lowers carbon emissions. After testing, the "aluminum-for-copper" technology has successfully achieved a 60% reduction in copper usage, a 43% reduction in weight, and at least a 20% reduction in costs. If widely adopted, this technology could help the industry save approximately 500,000 tons of CO2 annually.
 
Further analysis indicates that if the technology is fully promoted, it is expected to reduce CO2 emissions by about 850,000 tons per year, providing crucial support for the industry's transition to a low-carbon future.
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