During the energy transition, a large number of copper-intensive technologies have been deployed, resulting in a doubling of global copper production. The global mining giant BHP reported on Monday (September 30) that energy transition is expected to increase copper demand by one million tons annually by 2035. BHP‘s Chief Commercial Officer Rag Udd explained that the company anticipates a 70% increase in copper demand by 2050, reaching 50 million tons per year. Electric vehicles (EVs) remain the primary copper-intensive technology in the energy transition. The report notes that EVs are expected to increase the share of copper demand in the transportation sector from 11% in 2021 to 20% by 2040.
Thanks to numerous technological advancements and the increased use of alternative materials like aluminum, the copper intensity in passenger electric vehicles has been steadily declining over the past decade.
According to data from Benchmark Mineral Intelligence, the copper intensity per vehicle is expected to decrease by nearly 38 kilograms, from 99 kilograms in 2015 to 62 kilograms by 2030.
One of the most important factors driving this decline is frugality, as engineers and manufacturers continuously improve the efficiency and performance of various components, thereby reducing copper usage. A key example is battery production, where the thickness of copper foil used for battery anodes has noticeably decreased.
In 2015, Benchmark estimated that the copper foil usage per vehicle was slightly above 41 kilograms (with an average thickness of 10 microns), but by 2030, as manufacturers continue to adopt thinner copper foil, it is expected that copper foil usage will drop to 26 kilograms.
Similarly, automotive wiring harness systems have become more localized, with advancements in high-voltage harnesses and modular integration reducing the copper content in harnesses. The amount of copper used in harnesses has decreased from 30 kilograms per vehicle in 2015 to an estimated 17 kilograms by 2030.
Updated, more compact power electronics and improved thermal management in motors and charging cables also contribute to the reduction of copper usage. Alternatives are also playing a role, with materials like aluminum increasingly used in components such as busbars, wiring harnesses, and charging cables. Aluminum’s lighter weight and lower cost make it a practical alternative to copper in certain applications, although the additional space required to achieve the same conductivity can limit the use of aluminum in some cases.
Benchmark estimates that the amount of copper used in automotive wiring harnesses has decreased by 30% from 2015 to 2024.
Despite the decrease in copper usage per vehicle, the outlook for copper demand in the electric vehicle sector remains strong due to the industry’s growth.
Benchmark’s analysis indicates that by 2030, copper demand driven solely by electric vehicles will exceed 2.5 million tons, ensuring that copper will play a key role in the transition to a low-carbon future.
