Spanish researchers have developed a new material that could significantly reduce the weight of electrical systems in electric vehicles (EVs), drones, and aircraft. The breakthrough, published in Science and led by the Institute of Nanoscience and Materials of Aragon and the IMDEA Materials Institute, involves a chemical doping process that boosted carbon nanotube conductivity by 17 times while keeping the fibers structurally intact.
At ambient temperature, the doped fibers achieve about 40% of copper’s electrical conductivity. However, on a weight-adjusted basis, their specific conductivity exceeds that of aluminum. The fibers weigh roughly one-sixth of copper while offering about five times the tensile strength. Previous versions of these fibers were noted for being tough and lightweight but lacked sufficient current-carrying capacity, making this conductivity gain the key advancement.
The improvement came from treating the fibers with tetrachloroaluminate (AlCl4-), a dopant that introduces charge carriers without disrupting the atomic lattice—a long-standing challenge. Preserving structural integrity was critical because a conductor that fails in service has no practical value.
The implications for EVs are substantial. Modern EVs carry significant copper loads, especially in the thick wiring bundles that manage high-voltage power. Replacing part of that copper with a lighter material reduces vehicle mass and extends range. Lower resistivity at operating temperatures also cuts heat buildup. In drones, reducing cable mass directly translates into longer flight time, and for aircraft developers, weight savings yield outsized returns.
The material performs reliably in dry conditions and shows acceptable moisture tolerance, key factors 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 challenges are manufacturing: producing consistent fibers at scale, ensuring hardware compatibility, and establishing a cost profile competitive with conventional metals. If these issues can be resolved, the technology could move from 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 switching from copper economically viable.
