Galvorn CNT vs. Copper vs. Aluminum
In the aerospace industry, every gram counts. From commercial airliners to uncrewed aerial vehicles (UAVs) and satellites, reducing weight while maintaining performance is a constant challenge. Traditional wiring materials like copper and aluminum have long been the standard, but their limitations—weight, durability, and conductivity trade-offs—are pushing engineers to seek alternatives. Enter Galvorn carbon nanotube (CNT) wiring, a revolutionary material that’s lighter, stronger, and more versatile than copper and aluminum. In this post, we’ll explore why Galvorn CNT wiring is poised to redefine aerospace applications, comparing its properties to traditional metals and highlighting its advantages for the future of flight and space exploration.
The Problem with Copper and Aluminum Wiring
Copper and aluminum have been the go-to materials for aerospace wiring due to their conductivity and availability. However, they come with significant drawbacks:
- Weight: Copper has a density of 9 g/cm³, and aluminum, while lighter at 2.7 g/cm³, still adds significant mass. For example, a Boeing 787 contains about 500 km of wiring, weighing thousands of pounds, which impacts fuel efficiency and payload capacity.
- Durability: Copper is prone to corrosion and fatigue, especially in harsh aerospace environments like high-altitude humidity or space’s vacuum and radiation. Aluminum, though corrosion-resistant, has lower conductivity and strength.
- Space Constraints: Both materials have limited bend radii, making them bulky in tight spaces like avionics bays or satellite harnesses.
- Sustainability: Copper mining is resource-intensive, and supply chain shortages are driving up costs, with prices projected to rise further by 2030.
These challenges make copper and aluminum less than ideal for next-generation aerospace designs, especially in electric aircraft, lightweight satellites, and high-performance UAVs.
Enter Galvorn: The Carbon Nanotube Advantage
Galvorn, developed by DexMat, leverages carbon nanotube technology to overcome the limitations of traditional wiring. Made from aligned CNTs spun into fibers, Galvorn offers a unique combination of properties that make it a game-changer for aerospace. Let’s compare Galvorn to copper and aluminum across key metrics:
| Property | Galvorn CNT
(single filament fiber) |
Copper | Aluminum |
| Density (g/cm³) | 1.6 (80% less than copper) | 9.0 | 2.7 |
| Tensile Strength (GPa) | 3Â | 0.38 | 0.41 |
| Tenacity (N/tex) | 2 (50x stronger than copper, weight for weight) | 0.04 | 0.15 |
| Electrical Conductivity (MS/m) | ~10 (lower but sufficient for many applications) | 58 | 33 |
| Flex Life (Cycles) | 1,000,000+ (1000x copper) | ~10,000 | ~10,000 |
| Bend Radius | Ultra-tight (ideal for compact designs) | Limited | Moderate |
| Corrosion Resistance | No corrosion or oxidation | Prone to oxidation | Good, but less durable |
| Thermal Conductivity (W/m-K) | 450 (17% better than copper) | 385 | 237 |
The Galvorn properties noted above are for single filament fiber. For a complete listing of our products and their properties, please download the Galvorn specifications sheet.
Why Galvorn Wins in Aerospace
Unmatched Lightweighting
Galvorn’s density of 1.6 g/cm³ is a fraction of copper’s, enabling significant weight savings. For example, replacing copper signal wiring in a satellite (with ~20 km of wiring) could significantly reduce launch costs. In drones, the weight savings benefits include extended range and flight times, as well as payload capacity. In aircraft like the Airbus A350, lighter wiring translates to better fuel efficiency, potentially saving airlines thousands of tons of fuel annually.
Superior Strength and Durability
With a tensile strength of 3 GPa (and tenacity of 2 N/tex compared to copper’s 0.04) Galvorn withstands the vibrations, thermal cycling, and mechanical stresses of aerospace environments. Its flex life is 1000x greater than copper’s and ensures reliability in dynamic applications like UAV control surfaces or satellite solar panel hinges. Unlike copper, Galvorn doesn’t corrode, making it ideal for high-humidity or space conditions.
Compact and Flexible Design
Galvorn’s ultra-tight bend radius allows for compact wiring harnesses, critical in space-constrained environments like avionics or CubeSats. This flexibility simplifies installation and reduces the need for bulky connectors, further cutting weight and cost.
Thermal Performance
Galvorn’s thermal conductivity of 450 W/m-K surpasses copper’s 385 W/m-K, making it ideal for heat dissipation in high-performance systems like electric aircraft motors or satellite power buses. This property also supports applications in thermoelectric textiles for cooling systems.
Sustainability and Scalability
Unlike copper and aluminum, which relies on environmentally damaging mining, Galvorn can be made from abundant hydrocarbons, capturing carbon into a valuable solid material instead of releasing it into the atmosphere as harmful CO2, aligning with aerospace’s push for sustainability. Today DexMat is the leading provider of carbon nanotube wire, producing Galvorn with unmatched properties and utilizing a production process that can achieve kiloton scale. In fact, since Galvorn’s invention, DexMat has scaled up production capacity more than 3,000x, while bringing costs down 99.6%.
Key Aerospace Applications for Galvorn
Galvorn’s unique properties unlock a range of applications that copper and aluminum can’t match:
- Lightweight Data Cables: Galvorn’s signal wiring (e.g., ~70 grams per 100m) offers 50% weight savings over copper-braided RG316 cables, ideal for avionics and high-frequency data transfer in 5G-enabled aircraft. Learn more →
- EMI Shielding: Galvorn’s CNT braids provide superior electromagnetic interference (EMI) shielding at half the weight of copper, critical for protecting sensitive electronics in satellites and UAVs. Learn more →
- Antennas: Galvorn CNT thread antennas deliver 20x better radiation efficiency than copper at 1–2.4 GHz, perfect for satellite communications and the growing $7.13B super high-frequency market. Learn more →
- Piezoresistive Sensors: Integrated into composites, Galvorn enables real-time structural health monitoring, detecting stress or damage in aircraft wings or spacecraft hulls. Learn more →
Addressing Limitations
While Galvorn’s volumetric conductivity (~10 MS/m) is lower than copper’s (58 MS/m), this is less critical for signal wiring, shielding, or sensor applications where weight and durability take precedence. For high-current, small-diameter wires, copper may still be preferred, but Galvorn’s versatility covers most aerospace needs. Ongoing research, like KIST’s metal-free CNT motors, suggests future conductivity improvements, further expanding Galvorn’s potential.
The Future is Galvorn
As aerospace pushes toward lighter, more efficient, and sustainable designs, Galvorn CNT wiring stands out as a transformative solution. Its unparalleled strength, low weight, and environmental benefits make it a compelling alternative to copper and aluminum. Whether it’s reducing fuel costs in commercial jets, increasing range and payload for drones and UAVs, cutting launch expenses for satellites, or enabling next-gen electric aircraft, Galvorn is paving the way for the future of aerospace wiring.