Is Copper the material of the future? New applications in electronics and automotive industries

It is used in various industries, and thanks to its unique features and properties, it enables the development of numerous technologies. In this article, we will explain why it is called the material of the future and what the significance of copper is in the context of the development of electronics and the automotive industry.

The material of the future: understanding the unique properties of copper

Copper, valued for its unique attributes for centuries, is rising to the rank of a strategic material of fundamental importance for future innovations in this era of dynamic technological progress. Its unparalleled physicochemical properties, distinguishing it from other commonly used raw materials, make it a key element in advanced engineering applications, from energy systems to modern medical technologies.

First and foremost, it is one of the best electrical conductors. Copper boasts one of the highest electrical conductivity levels among technical metals. This fundamental property translates into the minimization of energy loss in transmission and distribution processes, which is crucial in the context of growing energy demand and the pursuit of increased energy efficiency. The use of copper in advanced power systems, including smart grids and electric vehicle (EV) infrastructure, is indispensable for ensuring the stability and reliability of energy supply. Furthermore, the high electrical conductivity of copper is of key importance in precise measuring instruments and advanced electronic circuits.  

But that's not all. Other exceptional copper properties include:

• High thermal conductivity: This makes copper crucial for temperature management in modern machines and systems. This property makes it an irreplaceable material in applications requiring efficient heat dissipation, from cooling systems in advanced processors and integrated circuits, through heat exchangers in industrial plants and HVAC (heating, ventilation, air conditioning) systems, to innovative solutions in renewable energy (e.g., solar collectors). Copper plays a vital role in optimizing the efficiency and durability of devices and systems. Its ability to quickly and effectively transfer heat is invaluable in maintaining stable operating conditions and preventing component overheating.  
• Corrosion and environmental resistance: Copper's natural resistance to corrosion and aggressive environmental conditions, including moisture, atmospheric pollutants, and the action of many chemical substances, ensures the long-term reliability of installations and devices made from this material. This property is particularly important in demanding environments such as outdoor electrical installations, the marine industry (shipbuilding, underwater installations), wind power (wind turbine components exposed to extreme weather conditions), and underground applications. The durability of copper minimizes maintenance and replacement costs, contributing to the economic efficiency of engineering projects.  
• Good ductility and malleability: These properties make copper processing simple. The good ductility and malleability of copper allow for easy cold and hot plastic working, enabling the formation of complex shapes and precise components. This property is crucial in the production of advanced elements for various industries, including power engineering, electronics (precision connectors, conductive elements), automotive (wire harnesses, cooling system components), and medicine (surgical instruments, implants). The ease of processing translates into lower production costs and greater freedom in engineering design.  
• High recycling potential: Contributing to the circular economy and sustainable development, copper is a material with almost unlimited recycling potential without losing its key properties. The ability to repeatedly recover and remelt copper scrap helps reduce the demand for primary natural resources, lowers CO2 emissions associated with mining and ore processing, and minimizes waste. The high copper recycling rate aligns with the concept of the circular economy and is an essential element of the sustainable development of the metals industry.  
• Antibacterial properties: Copper and its alloys destroy bacteria, viruses, and fungi. The unique antimicrobial properties of copper and its alloys (e.g., brass, bronze) are increasingly being studied and used in hygiene and healthcare applications. Copper ions exhibit strong biocidal effects against a wide range of microorganisms, including bacteria, viruses, and fungi. The use of copper surfaces in hospitals, public transport, and ventilation and air conditioning systems can help limit the spread of infections and improve sanitary safety.  

All these factors have a tremendous impact on the significant role of copper in the modern world. In practice, technological development without it would not be possible.

New applications of copper in electronics

In recent years, there has been a noticeable intensive development of electronics, which translates into dynamic changes in almost every area of life – from everyday functioning, through medicine and education, to industry and transport. The miniaturization of components, the increase in computing power, and the integration of devices with wireless technologies are making electronics increasingly intelligent, efficient, and ubiquitous. In this context, copper, with its unparalleled physicochemical properties, plays a crucial and often underestimated role, forming the foundation for further progress in this strategic industry.  

It is an indispensable element of:

• Motherboards and integrated circuits: In the complex architectures of printed circuit boards (PCBs) and advanced integrated circuits (ICs), copper performs a fundamental function as a conductive layer, enabling fast and efficient transmission of electrical signals with minimal resistive losses. The high electrical conductivity of copper is crucial for maintaining signal integrity and minimizing delays in increasingly complex and demanding electronic systems. Precise copper deposition techniques are used in lithographic processes to create microscopic conductive paths with optimal electrical parameters.  
• 3D printing: The innovative use of copper nanoparticles in conductive inks opens new possibilities in the field of 3D printing of electronics. This technology enables the fabrication of complex three-dimensional conductive structures, electrical circuits with non-standard shapes, and integrated sensors directly on various substrates. The use of copper in additive manufacturing allows for the prototyping and production of personalized electronic components with unique properties and functionalities, finding applications in flexible electronics and embedded systems, among others.  
• Cooling systems: Thanks to its excellent thermal conductivity, copper is used in heat sinks (e.g., for computers and servers) and modern liquid cooling systems.  
• Data centers: In the vast infrastructure of data centers, copper plays a multifaceted role, ensuring reliable power supply (high-current busbars), efficient cooling (components of HVAC and liquid cooling systems), and effective protection against electromagnetic interference (shielding of rooms and cables). The stability and reliability of the IT infrastructure, on which the modern digital economy is based, largely depends on the proper use of copper in key systems.  
• Energy storage: Copper plays a significant role in the development of advanced energy storage technologies, particularly in lithium-ion batteries, which are crucial for the growth of the renewable energy (RES) sector and electromobility. Copper foils and current collectors are used in the construction of battery cells, ensuring efficient current flow and minimizing energy losses.  
• Shielded cables: Copper conductors of this type reduce electrical noise, improve signal transmission, and limit electromagnetic radiation.  
• Semiconductor technology: Copper components are used in modern chips, e.g., in smartphones, as well as in sensors (e.g., temperature) and transducers (e.g., industrial and medical). Both its electrical properties (resistance changes with temperature) and thermal properties (high thermal conductivity for rapid temperature measurement) are utilized here. The durability and stability of copper's properties ensure the reliable operation of these key components in monitoring and control systems.  

It is worth adding that the unique features of copper have also been appreciated in aviation, space, and military technologies. It is used in radars (high-frequency conductive elements), communication systems (shielded cables, antennas), and in critical avionics, where reliability and resistance to extreme conditions are a priority.  

The role of copper in automotive and e-mobility development

The crucial role of copper extends far beyond the commonly discussed contribution to the development of electromobility, encompassing a wide spectrum of applications in internal combustion engine vehicles, hybrid, electric, and hydrogen vehicles, as well as in charging infrastructure and autonomous driving systems. It is a key component of electric powertrains – it is used in the production of power cables, coils, and inverters. It is also used in lithium-ion batteries and converters. It is a raw material that allows for intelligent engine management and its efficient operation for many years. How much copper is in an electric car? Up to 80 kg!

Copper is also essential in:

• Wiring harnesses: In modern vehicles, not only electric ones, copper wires ensure a reliable power supply to key systems, including engines, batteries, electronic control units (ECUs), safety, and comfort systems.  
• Engine and battery cooling systems: Its high thermal conductivity enables the prevention of overheating of batteries and engines.
• Radar and communication systems: Without copper, the proper functioning of Wi-Fi, Bluetooth, GPS, and sensors, e.g., in safety systems, would be impossible.
• Car components: Copper and its alloys are used in a variety of mechanical vehicle components, such as valves, bearings, seals, and elements of hydraulic systems. Its resistance to corrosion, high temperatures, and mechanical wear ensures the long-lasting and reliable operation of these critical components, contributing to increased vehicle lifespan.
• Vehicle charging systems: Copper components are found in power converters, inductive coils, and the charging connectors themselves, ensuring efficient and safe energy transfer. In fast charging stations that operate at high currents, the high electrical conductivity of copper is essential for minimizing energy losses and ensuring rapid battery charging.  
• Hydrogen fuel cells: It is used in cooling and connectors of hydrogen devices, which represent the future of the automotive industry.
• Autonomous vehicles: It is used in data transmission and power supply systems for advanced systems, which include numerous sensors, cameras, and radars. The high bandwidth and low resistance of copper connections are crucial for the efficient operation of these critical systems that form the foundation of autonomous driving.

Is a well-known car manufacturer launching a modern electric, hybrid, or hydrogen car? You can be sure that it largely consists of copper. Of course, let's not forget about internal combustion engine vehicles, which are still hugely popular and in which the use of copper is also widespread. It is used, among other things, in valves, pistons, and engine cooling systems.

Electris – Serving the Development of  Energy, E-mobility and others industries

The development of the automotive industry, power engineering, electronics, and other industries means that the demand for copper is constantly growing.

At Electris, we have been involved in the processing of copper and aluminum for over 20 years. We offer components used in energy production and distribution, in the development of transport, the railway industry, in the development of data centers and AI, and in the production of electric vehicles, charging stations, and many other modern technologies. To meet the expectations of the most demanding customers, we implement innovative solutions such as copper element lamination, galvanizing technologies (nickel plating, silver plating, or galvanic tin plating), epoxy painting, and combining two types of coatings with different properties on one element.  

If you need to order dedicated copper products for your company, please contact us and present your needs. Write to us at sales@electris.pl