Spanish Researchers Develop Carbon Nanotube Material That Could Slash EV Weight and Boost Range

A team of Spanish researchers has developed a new material that could transform electric vehicles by dramatically improving carbon nanotube conductivity. Published in the journal Science, the research from the Institute of Nanoscience and Materials of Aragon and the IMDEA Materials Institute focuses on a chemical doping process that boosted nanotube conductivity 17-fold while keeping the fibers structurally intact.

At ambient temperature, the doped fibers reach about 40% of copper's electrical conductivity. On a weight-adjusted basis, their specific conductivity exceeds aluminum. The fibers weigh roughly one-sixth of copper while offering about five times the tensile strength. Earlier versions of these fibers were tough and lightweight but lacked current-carrying capacity, making this conductivity gain a critical development.

The improvement came from treating the fibers with AlCl4-, a tetrachloroaluminate compound that acts as a dopant. Introducing charge carriers without disrupting the atomic lattice had been a major challenge, and the researchers say this method solves it. Preserving structural integrity was as important as the conductivity gain, since a conductor that fails in service has no practical value.

Modern EVs carry a significant copper load, especially in thick wiring bundles that manage high-voltage power. Replacing some 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 translates directly into longer flight time, and for aircraft developers, trimming weight yields outsized returns.

The material holds up reliably in dry conditions and shows acceptable moisture tolerance, properties important 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 exceed aluminum's conductivity on an absolute basis.

The remaining challenge is manufacturing: producing consistent fibers at scale, ensuring hardware compatibility, and establishing a cost profile competitive with conventional metals. If those problems can be solved, 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 if this new material becomes commercially available at scale and at price points that make the switch from copper economically viable.