The commercial drone industry is soaring. Driven by increasing adoption across sectors like agriculture, logistics, and infrastructure inspection, the global market size was valued at USD 32.5 billion in 2023 and projected to register a CAGR of over 10% from 2024 to 2032. A key challenge in drone design is balancing performance, range, and payload capacity, all of which are heavily influenced by weight. Here we'll discuss the benefits of Galvorn carbon nanotube (CNT) wire for drone wiring.
Enter Galvorn, the lightest, strongest, and most flexible conductive material on the planet.
Galvorn CNT fibers combine electrical conductivity (~10 MS/m) with exceptional strength (3 GPa), flexibility, and low density (~1.6 g/cm³). Galvorn CNT fibers not only have the best properties on the market (including exceptional thermal conductivity), but we produce them via wet-spinning, which is a proven highly scalable technology. The key advantages of its high-performance properties include:
- Light weight: With 80% less weight than copper and 96% less weight than copper-based EMI shielding, Galvorn can offer significant lightweighting benefits in wire and cable applications. Our wire and cable partners have validated that Galvorn is suitable for signal and short-range power transmission, while our work with NASA found that Galvorn EMI shielding reduces overall shielded wire mass by 40-60%.
- Superior durability: 50x stronger than copper, Galvorn's unique combination of traditional carbon fiber strength and textile flexibility results in superior durability in the application, as well as potential efficiencies in manufacturing, distribution and installation.
- Space-saving: Galvorn wiring solutions can be installed in much tighter spaces due to their extremely small bend radius, making more efficient use of space overall.
Let’s discuss the potential impact of Galvorn wire and cable in commercial drones.
The Power of Galvorn CNT Wire
Lightweight Design
Galvorn carbon nanotube wires, made from Galvorn CNT fibers, are a game-changer due to their remarkable weight reduction (Galvorn is 80% less dense than copper). This drastic reduction in weight directly impacts the overall mass of a drone, enabling designers to allocate weight savings to other critical components, such as larger batteries, enhanced sensors, or increased payload capacity.
Conductivity for Signal and Power
Galvorn CNT fibers (10 MS/m)Â formed into wire and cable are highly effective for signal transmission and short-range electrical power delivery. While not as conductive as copper (which has a conductivity of ~59 MS/m), Galvorn wires are more than adequate for transmitting data between onboard systems or powering low-to-moderate current components over short distances. This makes them ideal for applications like sensor networks, control systems, and communication modules in drones, where weight savings is critical. High conductivity is not always needed, and often less density or more flexibility is preferable to higher conductivity.
In fact, a conductivity of ~2 MS/m is a practical minimum for most drone applications, covering signal transmission (low currents, short lengths) and short-range power delivery (moderate currents, short lengths). This assumes typical wire areas (0.1-2 mm²) and lengths (0.1-2 m). Higher conductivities (e.g., 5-8 MS/m) provide more use cases for higher currents or slightly longer runs.
Galvorn fibers can reach conductivities up to 10 MS/m. When these fibers are processed into yarns, which allows for practical wire diameters and flexibility, the overall conductivity of the yarn/wire assembly typically ranges from 3-7 MS/m, depending on the specific construction and fiber fill.
Download the Galvorn spec sheet here.
Superior EMI Shielding
Electromagnetic interference (EMI) is a significant concern in drones, where sensitive electronics operate in close proximity. Traditional copper-braided shielding is effective but heavy. Galvorn CNT films, when used as EMI shielding, have been demonstrated to be 96% lighter than copper equivalents and can reduce the overall mass of a shielded wire by 40-60%. This lightweight shielding maintains robust protection against EMI, ensuring reliable operation of critical systems without the weight penalty of copper.
Superior Performance at High Frequencies
High-frequency wiring in drones is crucial for reliable communication and control systems. Used for transmitting data like video feeds, telemetry, and control commands between the drone and ground, as well as onboard sensors, these specialized shielded wires minimize signal loss and EMI at MHz to GHz frequencies. Essential for FPV cameras, GPS, and wireless transceivers, this wiring ensures real-time responsiveness and navigation accuracy in applications such as aerial photography, surveying, and autonomous operations. This study found that Galvorn exhibits superior performance compared to copper at high-frequency.
Benefits for Commercial Drones
Extended Range and Flight Time
The most immediate benefit of using Galvorn CNT wires is the reduction in drone weight, which directly translates to improved range and flight time. For battery-powered drones, less weight means lower energy consumption during flight, allowing for longer missions or the ability to cover greater distances. For example, a ~4 kg drone that previously carried 500 grams of copper wiring could reduce that to 100 grams with CNT wires, potentially increasing flight time by 10-20% depending on the drone’s design and battery capacity.
Increased Payload Capacity
Weight savings from Galvorn CNT wires can also be redirected to increase payload capacity. For delivery drones, this could mean carrying heavier packages, while for inspection or agricultural drones, it could allow for additional sensors or equipment. This flexibility enhances the versatility and commercial viability of drones across various industries.
Enhanced Agility and Efficiency
Lighter drones are more agile, with improved maneuverability and responsiveness. This is particularly valuable for applications requiring precision, such as cinematography or search-and-rescue missions. Additionally, reduced weight lowers the power required for hovering or rapid maneuvers, further improving energy efficiency.
Durability and Environmental Resistance
Galvorn CNT wires exhibit excellent mechanical strength and resistance to environmental factors like corrosion and temperature extremes (watch Galvorn continue to conduct electricity even as a blow torch flame is put to it). Unlike copper, which can oxidize or degrade over time, CNT wires maintain performance in harsh conditions, increasing the lifespan and reliability of drones operating in challenging environments, such as marine or industrial settings.
Practical Applications in Drone Design
Wiring for Control Systems
The conductivity and low weight of Galvorn CNT wires make them ideal for wiring drone control systems, including flight controllers, GPS modules, and communication antennas. These systems require reliable signal transmission with minimal latency, which Galvorn CNT wires can deliver without adding unnecessary mass.
Power Distribution
For short-range power distribution, such as powering motors or onboard electronics, Galvorn CNT wires offer a lightweight alternative to copper. While their lower conductivity limits their use for high-current applications like long-distance power transmission, they are well-suited for compact drone designs where space and weight are at a premium.
EMI Shielding for Sensitive Components
Drones rely on sensitive electronics, such as cameras, LiDAR, and radio transceivers, which are susceptible to EMI. Galvorn CNT shielding films can be integrated into wiring harnesses or wrapped around critical components, providing robust protection with minimal weight. This ensures consistent performance, even in environments with high electromagnetic noise, such as urban areas or near power lines.
An Opportunity for the Commercial Drone Industry
Galvorn carbon nanotube wires represent a transformative opportunity for the commercial drone industry. By slashing weight by up to 80% compared to copper, offering solid conductivity for signal and short-range power needs, and providing lightweight EMI shielding, CNT wires enable drones to fly farther, carry more, and operate more efficiently. The future of drones is lighter, smarter, and more capable—with Galvorn.