Scientists Seek to Leverage Wiring Innovations to
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Posted On: 04/09/2025 5:33:04 PM
Scientists Seek to Leverage Wiring Innovations to Boost EV Efficiency and Range
Electric vehicles (EVs) are becoming more popular every day, but they still face a big challenge; weight. Compared to traditional cars that use petrol or diesel, EVs are much heavier. One major reason for this is their large battery packs. For example, the Chevrolet Silverado EV weighs nearly 9,000 pounds, making it one of the heaviest vehicles on the road.
But scientists believe that even small changes can make a difference. That’s why researchers in Norway are exploring ways to reduce EV weight by focusing on something many people don’t think about: wiring.
Most EVs use copper for wiring because it’s a great conductor of electricity. It’s flexible, affordable, and widely available. However, copper is heavy. In a typical passenger EV, copper wiring can weigh about 183 pounds. In larger vehicles like electric buses, the wiring can add more than 800 pounds.
That’s a lot of extra weight, and every pound matters. Reducing this can help make EVs more efficient and increase how far they can travel on a single charge.
To solve the weight issue, scientists are looking at aluminum as an alternative. Aluminum is much lighter, about one-third the weight of copper. This makes it a good option for reducing the overall weight of an EV.
However, aluminum isn’t perfect. It’s harder to weld, and welding can make it brittle. This can cause electrical problems, which is a serious issue in any vehicle.
To avoid the problems that come with welding, researchers at the Norwegian University of Science and Technology (NTNU) have created a new method. It’s called hybrid metal extrusion and bonding. This technique uses friction and pressure, not heat, to bond copper and aluminum together.
By avoiding melting the metals, this process prevents the formation of weak spots known as “intermetallic compounds.” The result is a stronger and more reliable connection between the two metals. This method makes it possible to use lighter aluminum in EV wiring without losing safety or performance.
Even though using aluminum can reduce wiring weight, the overall weight reduction may still be small. That said, every bit helps. Lighter vehicles use less energy, which means they can go further without needing to recharge.
Some experts believe that using smaller battery packs could be an even better solution for reducing weight. Smaller batteries would cost less and reduce wear and tear on tires. But for this to work, charging stations need to be more common and reliable. If people can charge their EVs easily and quickly, they won’t need to carry around such large batteries.
Electric vehicles are the future, but they need to become lighter and more efficient to truly replace traditional cars. By improving the way EVs are wired and using new materials like aluminum, scientists hope to boost range, reduce costs, and make these vehicles even better. This research shows that sometimes, even small changes, like lighter wires, can have a big impact.
EV manufacturers across the board, such as Mullen Automotive Inc. (NASDAQ: MULN), are likely to give serious thought to any innovation like tweaking how wiring is done that promises to boost EV efficiency, cut production costs and make the vehicles more appealing to motorists.
NOTE TO INVESTORS: The latest news and updates relating to Mullen Automotive Inc. (NASDAQ: MULN) are available in the company’s newsroom at https://ibn.fm/MULN
Please see full terms of use and disclaimers on the TechMediaWire website applicable to all content provided by TMW, wherever published or re-published: https://www.TechMediaWire.com/Disclaimer
Electric vehicles (EVs) are becoming more popular every day, but they still face a big challenge; weight. Compared to traditional cars that use petrol or diesel, EVs are much heavier. One major reason for this is their large battery packs. For example, the Chevrolet Silverado EV weighs nearly 9,000 pounds, making it one of the heaviest vehicles on the road.
But scientists believe that even small changes can make a difference. That’s why researchers in Norway are exploring ways to reduce EV weight by focusing on something many people don’t think about: wiring.
Most EVs use copper for wiring because it’s a great conductor of electricity. It’s flexible, affordable, and widely available. However, copper is heavy. In a typical passenger EV, copper wiring can weigh about 183 pounds. In larger vehicles like electric buses, the wiring can add more than 800 pounds.
That’s a lot of extra weight, and every pound matters. Reducing this can help make EVs more efficient and increase how far they can travel on a single charge.
To solve the weight issue, scientists are looking at aluminum as an alternative. Aluminum is much lighter, about one-third the weight of copper. This makes it a good option for reducing the overall weight of an EV.
However, aluminum isn’t perfect. It’s harder to weld, and welding can make it brittle. This can cause electrical problems, which is a serious issue in any vehicle.
To avoid the problems that come with welding, researchers at the Norwegian University of Science and Technology (NTNU) have created a new method. It’s called hybrid metal extrusion and bonding. This technique uses friction and pressure, not heat, to bond copper and aluminum together.
By avoiding melting the metals, this process prevents the formation of weak spots known as “intermetallic compounds.” The result is a stronger and more reliable connection between the two metals. This method makes it possible to use lighter aluminum in EV wiring without losing safety or performance.
Even though using aluminum can reduce wiring weight, the overall weight reduction may still be small. That said, every bit helps. Lighter vehicles use less energy, which means they can go further without needing to recharge.
Some experts believe that using smaller battery packs could be an even better solution for reducing weight. Smaller batteries would cost less and reduce wear and tear on tires. But for this to work, charging stations need to be more common and reliable. If people can charge their EVs easily and quickly, they won’t need to carry around such large batteries.
Electric vehicles are the future, but they need to become lighter and more efficient to truly replace traditional cars. By improving the way EVs are wired and using new materials like aluminum, scientists hope to boost range, reduce costs, and make these vehicles even better. This research shows that sometimes, even small changes, like lighter wires, can have a big impact.
EV manufacturers across the board, such as Mullen Automotive Inc. (NASDAQ: MULN), are likely to give serious thought to any innovation like tweaking how wiring is done that promises to boost EV efficiency, cut production costs and make the vehicles more appealing to motorists.
NOTE TO INVESTORS: The latest news and updates relating to Mullen Automotive Inc. (NASDAQ: MULN) are available in the company’s newsroom at https://ibn.fm/MULN
Please see full terms of use and disclaimers on the TechMediaWire website applicable to all content provided by TMW, wherever published or re-published: https://www.TechMediaWire.com/Disclaimer
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