Spanish Researchers Boost Carbon Nanotube Conductivity 17-Fold, Challenging Copper

Spanish researchers from the Institute of Nanoscience and Materials of Aragon and the IMDEA Materials Institute have developed a new material that dramatically improves carbon nanotube conductivity, potentially paving the way to replace copper wiring in electric vehicles, drones, and aircraft. Published in the journal Science, the breakthrough centers on a chemical doping process using a tetrachloroaluminate compound (AlCl4-) as a dopant, which boosted nanotube conductivity by 17-fold while preserving the structural integrity of the fibers. At ambient temperature, the doped fibers achieve about 40% of copper's electrical output, but on a weight-adjusted basis, their specific conductivity surpasses aluminum. The fibers weigh roughly one-sixth of copper yet offer five times the tensile strength, making them exceptionally lightweight and strong.

Previous versions of these carbon nanotube fibers were known for being tough and lightweight but lacked sufficient current-carrying capacity. The conductivity gain is the key advancement, achieved by introducing charge carriers without disrupting the atomic lattice—a long-standing challenge. Preserving structural integrity ensures the material can withstand real-world use without breaking down. In electric vehicles, copper wiring adds significant mass, especially in high-voltage bundles. Replacing copper with a lighter material reduces vehicle weight, extends range, and minimizes heat buildup due to lower resistivity at operating temperatures. For drones, lighter cables directly translate to longer flight times, and for aircraft, weight reduction yields outsized efficiency gains. The material also performs reliably in dry conditions and shows acceptable moisture tolerance, which is critical for transportation certification.

The remaining hurdles include scalable manufacturing, hardware compatibility, and achieving cost parity with conventional metals. If these challenges are overcome, the technology could transition from labs to the electrical systems of next-generation EVs and aircraft. Recycling infrastructure for these materials will also need development. Companies like Ferrari N.V. (NYSE: RACE) are watching closely to see if the material becomes commercially available at scale and economically viable for switching from copper. GreenCarStocks, a platform focused on EVs and green energy, highlights this innovation as a potential game-changer for the transportation sector, offering a glimpse into a future where lighter, more efficient electrical systems are possible.