At the heart of the electric vehicle (EV) revolution lies copper given its critical role in the entire value chain of the new global automobile revolution. Its strategic importance encompasses not just the production of electric vehicles, creation of charging infrastructure but also developing energy storage. Copper’s value in EV’s ecosystem stems from its low cost compared to alternate metals, coupled with high durability, malleability and conductivity.
EVs consume 80-100 kg of copper: much more than traditional internal combustion engine (ICE) vehicles (20-25 kg) and hybrid electric cars (40kg). Copper’s unmatched electrical conductivity at 59.6 MegaSiemens per meter (MS/m) at room temperature compares favourably with aluminium's 37.8 MS/m, copper’s closest alternative. This allows automobile manufacturers to pack in smaller copper components tightly ensuring higher efficiency as less power is lost through poor conductivity.
Although cheaper than copper, aluminium cables suffer from a disadvantage. It needs to have a double cross-sectional area than copper to conduct the same amount of electricity, thereby taking up more space. Additionally, copper is 100% recyclable, meaning it can be used time and time again without any loss of conductivity.
Copper windings are key in EV motors because it creates strong magnetic fields for better torque and speed. More copper in motors means smaller, tighter designs, reduced resistance and hence less wastage on producing heat —providing more energy for quick acceleration and long highway drives.
Similarly, EV inverters and controllers use copper busbars-- solid metallic strip or bar that distributes electrical power in a variety of systems to handle high-voltage power smoothly-- cutting losses by up to 20% compared to other materials. Hence, EVs with more copper get 10-15% better energy efficiency, which means longer real-world range even in tough conditions like cold weather or heavy loads.
Battery Boost
Lithium-ion batteries use copper foil in the anode to ensure better conductivity. Stronger, purer copper improves the electron flow by cutting internal resistance which results in super-fast charging—like 80% in just 20 minutes. Its higher thermal conductivity dissipates heat well ensuring that batteries remain safe from degradation and retains more than 90% capacity even after thousands of cycles. Optimised copper content in EVs sees 5-10% gains in battery efficiency, directly boosting how far an electric vehicle (EV) can travel on a single charge.
EV infrastructure
Additionally, copper also plays an important role in electric vehicle infrastructure. In fact, Wood Mackenzie, a leading global research, analytics, and consultancy firm tracking energy, renewables, metals, and mining industries estimates that the EV sector will need 250% more copper by 2030 just for charging stations alone. This growth is dependent on the belief that there will be more than 20 million EV charging points globally. Charging stations alone contain 0.7 kg of copper (for a 3.3 kW charger) or 8 kg (for a 200-kW charger).
Wiring and Durability Edge
Copper's low resistance ensures that EV wiring harnesses continue to handle massive currents-- more than 400 volts-- without voltage drops and fires. Thicker copper cables up to 370 kg ensures greater safety and performance in trucks or buses. Coppers corrosion resistance properties prolong its longevity: it can last for 20 to 30 years even in the most adverse conditions—lowering maintenance and total ownership costs.
Despite India’s focus on the electrification of its transport system, the copper’s supply crunch has the potential to derail India’s ambitious EV rollout target, inflate costs, and strain India’s foreign currency reserves. Geopolitics and breakdown in existing global supply chains can exacerbate the situation given Indonesia's ban on copper concentrate and China’s refining dominance.
India's copper consumption touched 1,878 kilotonnes in FY25, witnessing a 9.3% year-on-year, driven by EVs, renewables, and infrastructure. Analysts predict total demand reaching 3.24 million tonnes by FY30 in conventional sectors, plus 2,74,000 tonnes from energy transition—including EVs and battery storage.
Domestic production, however, continues to lag with the country producing approximately 497,000 metric tons of refined copper and importing 90% of its copper concentrates, a figure expected to touch 97% by 2047.
India’s challenge is not only rising demand but also constrained domestic refining capacity. Sterlite Copper, once India’s largest copper smelter and a major supplier to the power, infrastructure, and automotive sectors, played a critical role in supporting the country’s copper ecosystem and reducing dependence on imports. As EV adoption accelerates and copper demand surges, strengthening and restoring such domestic refining capabilities will be essential for securing affordable supply and ensuring that India’s green mobility ambitions are not constrained by global supply disruptions.
However, decisive reforms like streamlining mining auctions, clearances, and exploration via the National Mineral Exploration Trust—can unlock greenfield sites. There is also a need to incentivise private investment with FDI reforms and reopen earlier smelters. These initiatives can turn crunch into opportunity—securing jobs, energy security, and EV leadership. India must act swiftly to smoothen its green future.
Dilip Chenoy is the Former Secretary General, FICCI and Director General of the Society of Indian Automobile Manufacturers. Views expressed are the authors’ personal.