Aluminum Shunts—the Future for Mobility And Aviation

Energy System Aluminum Shunts—the Future for Mobility and Aviation

2026-01-13 Source: Wickeder Westfalenstahl | Translated by AI 1 min Reading Time

Related Vendors

The demands on energy systems in electric vehicles, aviation, and rail transport are continuously increasing. Higher currents, reduced weight, and maximum efficiency are the key parameters for the next generation of high-performance components. In this context, an innovation comes into focus: aluminum shunts.

Shunts with aluminum connectors are a perfect match for aluminum cables, which have long been the standard when it comes to weight reduction in mobile applications.(Image: Wickeder) — Shunts with aluminum connectors are a perfect match for aluminum cables, which have long been the standard when it comes to weight reduction in mobile applications.
(Image: Wickeder)

Aluminum has long been established in energy transmission—particularly in aviation and rail transport, where weight savings are crucial. Aluminum cables are standard, but connections to measuring components like shunts are often made with copper terminals. This leads to transition resistances, galvanic corrosion, and additional weight. The solution: shunts with aluminum terminals.

The Advantages at A Glance

No transition resistances—The material homogeneity between cable and shunt eliminates contact issues. This means less heat generation, higher efficiency, and longer lifespan of the connection.
Weight advantage—Aluminum is about 70 percent lighter than copper. In aviation, every gram counts—and in electric vehicles, every pound directly impacts range and energy consumption.
Resource conservation, sustainability—Aluminum is significantly more readily available, making the system more resource-efficient.
Corrosion resistance—With suitable surface treatments (e.g., nickel or tin coating), aluminum remains reliable even under extreme conditions.

Technological Challenges—And their Solutions

The plating of aluminum and the resistance alloy prevents oxidation and safeguards against contact resistance.(Image: Wickeder) — The plating of aluminum and the resistance alloy prevents oxidation and safeguards against contact resistance.
(Image: Wickeder)

Of course, aluminum also brings challenges: lower conductivity, oxidation, and mechanical stability. However, modern manufacturing technologies and intelligent designs solve these issues. Adjusted cross-sections compensate for the lower conductivity. Additionally, the plating of aluminum and the resistance alloy prevents oxidation and safeguards against contact resistance.

Fields of application

Electric vehicles: Battery management systems, high-current connections, and charging infrastructure benefit from the weight and efficiency improvements.
Aviation: Here, the combination of weight savings and reliability is a game-changer.
Rail transport: Aluminum shunts harmonize perfectly with existing aluminum conductors and reduce maintenance effort.

Aluminum shunts are more than just an alternative—they are the consistent, disruptive advancement for high-current applications in mobility and aviation. They combine efficiency, lightness, and cost advantages, setting new standards for the future of energy distribution.

Neuer Ansatz zur schnelleren Fahrzeugmodellierung

Subscribe to the newsletter now

Don't Miss out on Our Best Content

Business E-mail

Please enter a valid mailadress.

By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy. The consent declaration relates, among other things, to the sending of editorial newsletters by email and to data matching for marketing purposes with selected advertising partners (e.g., LinkedIn, Google, Meta)

Date: 08.12.2025

Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.

Consent to the use of data for promotional purposes

I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planck-Str. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here

Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.

Additionally, my consent also includes the processing of my email address and telephone number for data matching for marketing purposes with select advertising partners such as LinkedIn, Google, and Meta. For this, Vogel Communications Group may transmit said data in hashed form to the advertising partners who then use said data to determine whether I am also a member of the mentioned advertising partner portals. Vogel Communications Group uses this feature for the purposes of re-targeting (up-selling, cross-selling, and customer loyalty), generating so-called look-alike audiences for acquisition of new customers, and as basis for exclusion for on-going advertising campaigns. Further information can be found in section “data matching for marketing purposes”.

In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here. This does not apply to data matching for marketing purposes.

Right of revocation

I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://contact.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.