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What are the Advantages of PET Coated Aluminum Wire Compared to Copper Wire?

2026.05.14

Author：PET coated aluminium wire

The main advantages of PET coated aluminum wire compared to copper wire are its lightweight, low cost, and excellent corrosion resistance, making it particularly suitable for applications in weight-sensitive and high-humidity environments.

1. Lighter Weight:

Aluminum's density is approximately 30% that of copper. For the same length and conductivity, PET coated aluminum wire weighs only about half that of copper wire, significantly reducing the overall load on the wiring harness.

In fields with stringent weight reduction requirements, such as new energy vehicles and aerospace, using PET coated aluminum wire can effectively improve energy efficiency and battery life.

2. Lower Cost:

Aluminum is significantly cheaper than copper, and the PET coating process is mature, resulting in an overall manufacturing cost 30%-50% lower than copper wire with equivalent performance.

For large-scale cabling projects, using PET coated aluminum wire can substantially reduce material procurement and transportation costs.

3. Enhanced Corrosion Resistance:

The PET coating forms a dense insulating layer, effectively isolating moisture, oxygen, and salt spray, preventing aluminum core oxidation, and extending service life.

In humid, high-salt-spray, or chemically corrosive environments, its stability is superior to bare copper wire or ordinary enameled copper wire.

4. Superior Insulation and Safety Performance

PET itself is a high-performance engineering plastic with excellent electrical insulation, flame retardancy, and mechanical protection capabilities, reducing the need for additional insulation layers.

Compared to copper wire, which requires additional sheathing or PVC sheathing, PET coated aluminum wire offers higher integration, simplifying wiring structures and improving space utilization.

5. Adaptable to High-Frequency and Signal Transmission Scenarios

In high-frequency applications, utilizing the skin effect, current mainly concentrates on the conductor surface. PET coated aluminum wire can achieve near-copper wire transmission efficiency through optimized surface treatment.

Although its DC resistance is slightly higher than copper wire, this has a smaller impact in low-current scenarios such as signal lines and control lines.

Qingdao Chenan Machinery Co., Ltd. has the advantage of developing and producing rubber winding equipment, with higher technology than various equipment assembly manufacturers in the industry. For more information about PET coated aluminium wire, please contact us.

Company: Qingdao Chenan Machinery Co., Ltd.

Address: Yanjialing Industrial Park, East Chengma Road, Tongji New Economic Zone, Jimo District, Qingdao City, Shandong Province

Email: qdcajx@gmail.com