Copper is more expensive than aluminium mainly because it is far scarcer and harder to produce. Per tonne, copper has traded at more than 3.5 times the price of aluminium for much of the past five years, according to the IEA. Per amp of current carried, though, the gap is smaller, because aluminium needs a larger conductor. A rough calculation puts aluminium’s metal cost per amp at about one-seventh of copper’s at that price ratio.
Key Takeaways
- Copper is scarcer and slower to bring to market than aluminium.
- Per tonne, copper has cost more than 3.5 times aluminium (IEA).
- Per amp, aluminium metal can cost about one-seventh as much.
- Flexible charging cables still use copper for size and reliability.
Why Copper Costs More per Tonne
| Factor | Copper | Aluminium |
|---|---|---|
| World primary output, 2025 (USGS est.) | About 29 Mt refined | About 74 Mt from smelters |
| Ore and resources | Ore grades have fallen about 40% since 1991 (IEA) | Bauxite resources of 55–75 billion tonnes (USGS) |
| New supply lead time | About 17 years from discovery to production (IEA) | Smelters can be restarted or expanded faster |
| U.S. average price, 2025 (USGS) | About 480 ¢/lb (COMEX) | About 180 ¢/lb (U.S. ingot spot) |
U.S. prices in 2025 were affected by tariffs on both metals, so the U.S. ratio differs from global exchange ratios. The two U.S. series also measure different products, so treat them as indicative.
Cost per Amp: A Worked Comparison
Aluminium conducts about 60% as well as copper. To carry the same current with the same resistance, an aluminium conductor needs about 1.64 times the cross-section.
- Volume: 1.64 times copper’s.
- Mass: 1.64 × 2.70 g/cm³ ÷ 8.89 g/cm³ ≈ 0.50 of copper’s mass.
- Metal cost at a 3.5:1 price ratio: 0.50 ÷ 3.5 ≈ 0.14 of copper’s.
So aluminium can carry the same current for roughly one-seventh of the metal cost, in a conductor about 28% wider in diameter. That is why it is used in overhead lines and some building feeders.
Why Charging Cables Still Use Copper
- Size: a thicker cable is harder to handle and coil.
- Flex life: aluminium strands fatigue faster when bent daily.
- Terminations: aluminium oxidizes and creeps, so it needs connectors rated for it.
- Metal is a minor cost: about 1–2 kg of copper in a typical cable is a small part of a charger’s price.
The IEA notes that a 3:1 price ratio was long seen as the trigger for large-scale substitution, yet ratios above 3.5:1 have not caused a major shift. Our guides to supply wire size and charging cable types cover where each metal is acceptable. For cost structure, see what drives OEM charger unit cost.
What This Means for Buyers
Do not chase aluminium savings in a charging cable. If a supplier offers aluminium or copper-clad aluminium cores to cut price, ask how the cable is certified. EVDANCE uses copper conductors, including in the ACS1605PE 11 kW three-phase portable charger, and offers private label through its OEM program.
Frequently Asked Questions
How much more expensive is copper than aluminium?
Per tonne, more than 3.5 times for much of the past five years, per the IEA. The ratio changes with markets and tariffs.
Is aluminium wire cheaper per amp?
Yes, by metal cost, roughly one-seventh at a 3.5:1 price ratio, but it needs larger sizes and rated terminations.
Will aluminium replace copper in EV chargers?
The IEA notes aluminium already substitutes in some EV cabling, but flexible charging cables still favour copper.
Related Reading
- What Size Wire Do You Need for an EV Charger?
- Are All EV Charging Cables the Same?
- What Drives the Unit Cost of an OEM EV Charger
- How to Read an EV Charger Datasheet
