>Alternatively, doubling the battery voltage again to 1.5kV (and so halving the currents) might allow Hyundai to use more aluminium for the "wires", with a cost

>Alternatively, doubling the battery voltage again to 1.5kV (and so halving the currents) might allow Hyundai to use more aluminium for the "wires", with a cost saving over copper. This seems dubious, you're not going to be able to use aluminum for motor windings which is where the bulk of the copper in an EV is going to be. As for conductors between the battery, HV auxiliary devices, inverter, motor, charger, etc they could already use aluminum, it's not like they're space constrained on the gauge of cable between components. Aluminum is already more mass efficient than copper, you might need a thicker gauge to match the same resistance but that thicker aluminum is still lighter than copper and way cheaper. The problems with aluminum are oxidation and brittleness. Maybe eventually auto manufacturers will shift more towards aluminum bus bars between components with no relative movement but I don't see a big link here (haha, busbar puns) between ampacity and the choice between copper and aluminum.