{"id":20509,"date":"2026-06-25T10:23:58","date_gmt":"2026-06-25T08:23:58","guid":{"rendered":"https:\/\/came-italy.com\/?p=20509"},"modified":"2026-06-25T10:23:58","modified_gmt":"2026-06-25T08:23:58","slug":"winding-with-copper-or-aluminium-wire","status":"publish","type":"post","link":"https:\/\/came-italy.com\/en\/winding-with-copper-or-aluminium-wire\/","title":{"rendered":"Winding with copper or aluminium wire?"},"content":{"rendered":"<div style=\"margin: 35px 0 55px 0;\">\n<h2 style=\"margin-bottom: 30px; line-height: 1.5;\">Copper remains the most efficient choice for electric motor windings.<\/h2>\n<h2 style=\"margin-bottom: 30px; line-height: 1.5;\">Aluminium can reduce weight and material cost, especially when the price of copper has a large impact on the project.<\/h2>\n<h2 style=\"margin-bottom: 30px; line-height: 1.5;\">The conductivity of aluminium is about 61% compared to copper, so a larger conductor section is needed.<\/h2>\n<h2 style=\"margin-bottom: 0; line-height: 1.5;\">The correct choice depends on the required efficiency, size, work cycle, costs and application targets of the motor.<\/h2>\n<\/div>\n<p><a class=\"button\" href=\"mailto:marketing@came-italy.com\"><strong>CONTACT US FOR INFORMATION<\/strong><\/a><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>Copper or aluminium: a technical choice that nowadays also affects costs<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">The choice between copper and aluminium in asynchronous and synchronous windings <a href=\"https:\/\/came-italy.com\/en\/came-customer-relations-innovating-together\/\">is not just about electrical performance<\/a>. For the customer, it means assessing material cost, motor efficiency, weight, size and long-term reliability.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In a context in which copper has a high cost, <strong>aluminium may become an alternative worth considering in some applications. For us at Came, however, the assessment must always start from the motor design and application.<\/strong><\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>Copper offers the greatest efficiency, compactness and reliability<\/b><\/h2>\n<p><span style=\"font-weight: 400;\"><strong>Copper remains the reference material when the customer needs high performance. <\/strong>Its higher conductivity can reduce electrical losses, keep sections smaller and make motors more compact.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Copper is particularly suitable when the following are required:<\/span><\/p>\n<ul style=\"margin-bottom: 25px;\">\n<li style=\"list-style-type: none;\">\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">maximum efficiency;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">continuous use;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">high loads;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">compact motors;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">long service life;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">simpler and more robust connections.<\/span><\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">For the customer, copper may have a higher initial cost, but it can offer benefits throughout the motor life cycle when efficiency and operational continuity are a priority.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>Aluminium can reduce weight and material cost<\/b><\/h2>\n<p><span style=\"font-weight: 400;\"><strong>Aluminium can be attractive when the project requires lower weight or limited material cost.<\/strong> In fact, it has a much lower density than copper, and can make the component lighter.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Aluminium can be considered when the customer is looking for:<\/span><\/p>\n<ul style=\"margin-bottom: 25px;\">\n<li style=\"list-style-type: none;\">\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">lower material cost;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">lower weight;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">economic optimisation on high volumes;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">intermittent applications;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">low-power motors;<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">projects in which size is not critical.<\/span><\/li>\n<\/ul>\n<\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">In these cases, aluminium is not an inferior choice at all, it is a different choice, <a href=\"https:\/\/came-italy.com\/en\/which-ivic-to-choose-when-there-are-no-application-specifications\/\">to be designed correctly<\/a>.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>The limitation of aluminium is its lower conductivity<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">The main limitation of aluminium is its lower electrical conductivity compared to copper. An aluminium conductor must have a larger section for the same performance.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">This affects motor size, slot fill factor, connections, thermal management and the winding process. <strong>For the customer, it means comparing material savings with the entire project.<\/strong><\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>When to choose copper or aluminium<\/b><\/h2>\n<p><span style=\"font-weight: 400;\"><strong>Aluminium can be chosen when the economic benefit or weight reduction is more important than maximum absolute efficiency:<\/strong> it is especially suitable for applications with a strong focus on cost, intermittent use or limited power, or for projects in which the conductor section can be increased.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Copper, on the other hand, remains the most suitable choice when the customer wants the greatest efficiency, compactness and long-term reliability. It is the most suitable solution for motors intended to work continuously with high loads or in applications in which service life is a core requirement.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>Technical assessment reduces risks before industrialisation<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Changing the winding material can change the motor behaviour, and can affect the wire section, slot fill factor, insulation, heat dissipation and connection quality.<\/span><\/p>\n<p><span style=\"font-weight: 400;\"><strong>Therefore, the choice must be made before industrialisation, not when the project is already defined.<\/strong> During our <a href=\"https:\/\/came-italy.com\/en\/came-consultancy-to-improve-the-efficiency-of-a-cast-iron-motor-to-class-ie3\/\">technical support and feasibility<\/a> work, we at Came help the customer assess the material that is most consistent with the expected result.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2 style=\"margin-bottom: 22px; line-height: 1.45;\"><b>Copper for maximum performance, aluminium for lightness and limited costs<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">There is no absolute choice between copper and aluminium. Copper is the most suitable solution when the customer is looking for efficiency, compactness, durability and reliability. Aluminium can be considered when the project requires lower weight, limited material cost and greater dimensioning flexibility.<\/span><\/p>\n<p><span style=\"font-weight: 400;\"><a href=\"https:\/\/came-italy.com\/en\/how-came-customers-benefit-from-the-lean-project\/\">The best choice is the result of balancing<\/a> required performance, material cost, application constraints and customer targets.<\/span><\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<div style=\"width: 100%; float: left;\">\n<div style=\"float: left;\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-20451 alignleft\" style=\"border: 1px solid #f4792d;\" src=\"https:\/\/came-italy.com\/wp-content\/uploads\/2026\/06\/Screenshot-2026-06-11-130345.png\" alt=\"\" width=\"150\" height=\"173\"><\/div>\n<div style=\"float: left; margin-left: 20px;\">Article by:<br \/>\n<a href=\"https:\/\/www.linkedin.com\/in\/gianluca-pegoraro-3b8b5220\/?locale=en\">Gianluca Pegoraro<\/a><br \/>\nTechnical Director of Came<br \/>\n<a href=\"mailto:consulting@came-italy.com\">consulting@came-italy.com<\/a><br \/>\n<a href=\"tel:+39 0444 488282\">+39 0444 488282<\/a><\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Copper remains the most efficient choice for electric motor windings. Aluminium can reduce weight and material cost, especially when the price of copper has a large impact on the project. The conductivity of aluminium is about 61% compared to copper, so a larger conductor section is needed. The correct choice depends on the required efficiency, [&hellip;]<\/p>\n","protected":false},"author":14,"featured_media":20518,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"ngg_post_thumbnail":0,"footnotes":""},"categories":[1],"tags":[336,436,2636,2637,2588,1959,2638,2626,2589,376,2640,2590,2639,2611,253],"class_list":["post-20509","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized","tag-aluminium","tag-came-en","tag-copper","tag-efficiency","tag-electricmotors","tag-engineering","tag-feasibility","tag-industrialdesign","tag-industrialization","tag-innovation","tag-motortechnology","tag-productdevelopment","tag-projectoptimization","tag-reliability","tag-windings"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.8 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Winding with copper or aluminium wire? - Came Spa<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/came-italy.com\/en\/winding-with-copper-or-aluminium-wire\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Winding with copper or aluminium wire? - Came Spa\" \/>\n<meta property=\"og:description\" content=\"Copper remains the most efficient choice for electric motor windings. Aluminium can reduce weight and material cost, especially when the price of copper has a large impact on the project. The conductivity of aluminium is about 61% compared to copper, so a larger conductor section is needed. 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Aluminium can reduce weight and material cost, especially when the price of copper has a large impact on the project. The conductivity of aluminium is about 61% compared to copper, so a larger conductor section is needed. 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