The Need
Current lightweight conductors, such as copper and aluminum, face limitations in specific electrical conductivity, flexibility, and thermal management, especially for demanding applications in electrified transportation and aerospace. There is a critical need for conductors that combine high ampacity, low density, and tunable thermal/electrical properties to enable next-generation motors, generators, and superconducting systems.

The Technology
This technology, developed by OSU engineers, utilizes a conductive polymer coating (optionally with carbon-based molecules) applied to carbon nanotube (CNT) yarns or superconducting strands. The process enhances thermal and electrical sharing between strands, improving current distribution and stability. The composite wire achieves higher specific conductivity than copper, maintains flexibility, and allows for tunable anisotropy in thermal and electrical properties, making it ideal for advanced electrical systems.

Commercial Applications
• Lightweight motor and generator windings for aerospace and automotive sectors
• High-performance superconducting cables and coils
• Power transmission lines with reduced weight and improved reliability
• Advanced electronic devices requiring flexible, high-conductivity wiring

Benefits/Advantages
• Specific electrical conductivity exceeds copper by 11%
• Maintains >95% CNT content for superior flexibility
• Enhanced ampacity and thermal stability for safer, longer-lasting operation
• Tunable anisotropy enables reduced eddy current losses and optimized thermal management