Rewiring responsibility: are EV charging cables sustainable?

Whilst often overlooked, these components carry material, environmental, and manufacturing challenges that demand innovative solutions.

James Louw, Director of Engineering at EV Cables, offered a detailed perspective on how the company is addressing sustainability concerns in EV cable production, from materials sourcing to lifecycle assessments.

Replacing plastics with bio-based alternatives

Traditional EV charging cables rely heavily on petroleum-based plastics like PVC, which pose environment challenges both during manufacturing and at end-of-life. In response, EV Cables has been exploring the use of biodegradable and recyclable alternatives.

Louw explained: “The push toward biodegradable and recyclable materials for EV charging cables reflects the ongoing commitment to sustainable innovation in electric vehicle infrastructure. To that end, we at EV Cables are exploring bio-based polymers like polylactic acid (PLA) and bio-polyamides, sourced from renewables such as corn or castor oil, which will replace traditional petroleum-based plastics like PVC.”

He noted that EV Cables had already introduced recyclable thermoplastics in some of its products: “We already use recyclable thermoplastics, namely thermoplastic elastomers (TPEs) for certain components within our Wottz Type 2 plug and are investigating other natural fibre composites, such as hemp or flax reinforcements, that can craft cable components that can either decompose responsibly or be reused.”

However, the implementation of these alternatives is a far from straightforward process: “Biodegradable materials often fall short in delivering the durability, thermal resistance, and flexibility required for cables to handle high voltages, harsh weather, and constant use. This is critical for customer safety and satisfaction and, to that end, many of these new materials would not pass the various tests needed to be formally certified,” said Louw.

There are also commercial and regulatory barriers. Greener materials often cost anywhere from 20-50% more to produce, while recycling infrastructure for mixed-material cables remains limited. “The lack of robust recycling systems for complex cable components, coupled with unclear regulatory standards, complicates scalability,” he added.

Reducing copper dependency

Copper is integral to all things EV cables, yet the price and environmental cost of copper are fuelling a shift toward alternative conductors. As Louw pointed out: “We recognise the pressing need to reduce reliance on copper in EV charging cables due to its environmental and economic implications – mining is resource-heavy, and prices fluctuate around £7,000–£8,000 per ton.”

To mitigate these challenges, EV Cables is investigating material alternatives like aluminium, which offers cost and sustainability benefits but only around 60% of copper’s conductivity. According to Louw: “Pure aluminium cables do have significant drawbacks when it comes to overall cable size and flexibility, so we are looking at how copper content can be reduced through the use of hybrid copper/aluminium conductors.”

He acknowledged the balancing act required to meet both environmental goals and customer expectations: “We know every choice involves a trade-off: we’re passionate about getting more people into EVs and using sustainable materials, but leaning too hard one way can limit the other. It’s a delicate balance—staying true to our customers, the planet, and our mission – a synergy of purpose.”

Manufacturing efficiency and lifecycle assessments

Beyond materials, the sustainability of a product is shaped by how it is manufactured. EV Cables has embedded efficiency into its business model through just-in-time production methods and flexible stock management.

“We have pioneered a just-in-time, made-to-order manufacturing model that allows us to be efficient in our stock holdings and gives us the flexibility to offer thousands of SKUs from just a few core components,” said Louw.

Streamlining the production process has delivered measurable improvements:

“Streamlined production – using precision techniques or automation – can cut material losses by up to 15%, while lean strategies like just-in-time prevent overstocking, especially as industries shift to greener materials. Energy-efficient equipment can also shrink carbon footprints by 20–30%, meeting rising eco-conscious demands.”

Lifecycle assessments (LCAs) are also becoming essential to the company’s approach.

“LCAs offer a full view of a product’s environmental impact, highlighting issues like resource-heavy inputs or disposal challenges, and guiding shifts – such as adopting recyclable materials to reduce waste by 40%.”

While challenges remain, including upfront investment and data complexity, EV Cables views LCAs as a path to sustainable relevance. “These tools help companies balance profitability with planet-friendly innovation, ensuring long-term relevance and responsibility,” Louw concluded.

The road ahead

As governments tighten regulations and consumers become more environmentally aware, the sustainability of every EV component—down to the cables—will come under increasing scrutiny. For companies like EV Cables, innovation lies not just in performance, but in making the entire product lifecycle cleaner, leaner, and smarter.

By combining material science, manufacturing efficiency, and thoughtful trade-offs, the company is working to ensure that EV infrastructure does not just support cleaner transport but also embodies the same sustainability it enables.