Introduction
When designing or selecting EV charging cables, one of the most critical decisions involves the type of conductor material used inside the cable. The two most common options are copper core and aluminum core.
Your choice of core material directly affects:
- Electrical performance
- Current-carrying capacity
- Durability and mechanical strength
- Total product cost
So, which one is better for your use case—copper or aluminum? This article offers a detailed comparison.
Copper vs. Aluminum Core: Comparison Table
| Criteria | Copper Core | Aluminum Core |
|---|---|---|
| Electrical conductivity | Very high (~100%) | Lower (~60% of copper) |
| Heat resistance | Excellent, minimal expansion | Expands more under high temperature |
| Weight | Heavier | 30–50% lighter |
| Mechanical strength | Ductile, bendable, very durable | More brittle, needs careful handling |
| Long-term stability | Highly resistant to oxidation | Prone to oxidation without protective coating |
| Cost | Significantly higher (~30–50%) | Much lower cost |
| Common use cases | High-end EVs, DC fast charging cables | Standard EVs, AC home charging, long cable runs |
When to Choose Copper Core
- When using DC fast charging systems (50kW–350kW+)
- When electrical efficiency and low resistance are critical
- In harsh environments (heat, vibration, or exposure)
- When the goal is maximum lifespan and safety
When to Choose Aluminum Core
- For residential AC charging or mid-power systems
- When cost optimization is a priority (especially for long cables)
- When weight reduction matters (e.g., 2-wheelers, scooters)
- For fixed installations with little movement or flexing
Expert Recommendations
| Real-World Scenario | Recommended Core | Reason |
|---|---|---|
| DC fast charging stations | Copper | Better current flow, safety, and heat performance |
| Home AC chargers (private users) | Aluminum | Cost-effective, sufficient for low to mid power |
| Premium EVs or commercial fleets | Copper | Durability and lower energy loss over time |
| E-scooters or 2-wheeled EVs | Aluminum | Lightweight and budget-friendly |
| Large-scale, cost-sensitive projects | Aluminum (with coating) | Affordable, as long as oxidation is managed properly |
Conclusion
Copper cores offer superior performance and durability, making them ideal for high-power, high-reliability EV charging.
Aluminum cores provide a cost-effective solution for standard use cases where weight and budget are more important than peak performance.
Choosing the right core depends on your application, operating environment, and investment priorities.
Still unsure which EV cable core is best for you?
Contact us to:
- Get custom recommendations for your EV or charging station
- Request product samples and technical datasheets
- Receive quotes for both copper and aluminum core options based on your specs
