COPPER: The Once And Future King
- Edward Tierney
- Apr 29
- 3 min read
Silver Inks: Under Pressure
Silver-based inks are the current go-to for printed electronics. They’re reliable, highly conductive, and work across a range of substrates. But cracks are starting to show.
Silver prices are unpredictable. Supply chains are exposed to geopolitical risks—and then some these days. Meanwhile, demand for ever smaller electronics is only pushing prices higher. Case in point: silver spent much of the past decade hovering around $15/oz. Today, it’s closer to $33/oz, with forecasts as high as $50/oz within a few years.
While supply chain concerns and surging prices are starting to show up in headlines, several strategic issues often get overlooked:
Innovation is stalling. Silver’s dominance has led to inertia, even as flexible and wearable electronics demand new material properties.
Recycling is limited. Copper can be recovered and reused far more efficiently than silver.
Regulations are tightening. ESG standards are pushing manufacturers toward cleaner, more ethical alternatives.
In short: relying on silver is starting to look less like a safe bet—and more like a growing risk.
Copper: From Underdog to Industry Leader
Copper’s conductivity is well-known, second only to silver. If conductivity were scored from 0–100, silver ranks 100 and copper 97. For decades, subtractive manufacturing favored copper because it was cheaper, readily available, and corrosion-resistant under traditional processing methods.
Today, with additive manufacturing, early attempts to use copper inks struggled with oxidation: when copper oxidizes, conductivity drops.
That’s changing. Recent advances have overcome these hurdles, making copper inks a viable, high-performance alternative:
Surface-engineered nanoparticles resist oxidation and keep conductivity stable.
Low-temperature sintering allows copper inks to be used on plastics, textiles, and other heat-sensitive materials.
Compatibility with standard inkjet, screen, and spray printing equipment.
This isn’t just about cutting costs. It’s about expanding design options and positioning production for future demands.
The Value Proposition
Why copper inks are gaining ground:
1. Cost Savings
Copper is dramatically less expensive—around $0.28/oz compared to silver’s $33.50/oz. For high-volume production, that’s a game-changer. Many manufacturers are seeing material costs drop by 30–60% after switching. Side note: Copper prices are also rising due to increased demand in electronics—but still remain a fraction of silver's cost.
2. Sustainability
Copper is abundant and easily recycled. New copper ink formulations are also less resource-intensive to produce, helping to cut the environmental footprint of electronics manufacturing.
3. Design Flexibility
Today’s copper inks support:
Ultra-fine lines (sub-10μm) for dense circuitry
Low resistance (below 0.1Ω/sq), matching silver’s electrical performance
Stretchability (up to 150%), ideal for wearables and flexible sensors
Integration with 3D and multi-material printing for more complex architectures
4. Compliance
Copper is non-toxic and easier to recycle, simplifying compliance with tightening environmental and materials regulations. The EU, for example, is beginning to apply PCB-style recycling and toxicity standards to printed electronics.
Where Copper Inks Are Making an Impact
Copper inks are moving from lab experiments to real-world deployment across industries:
Solar cells: Copper inks are helping lower the cost of photovoltaic cells, supporting the broader drive for greener energy.
RFID and antennas: Fine, reliable copper traces are making RFID production more affordable and scalable.
Semiconductor packaging: Copper MOD inks are replacing traditional plating, cutting energy use and improving ESG outcomes.
PCBs: Printed copper traces offer a cleaner, more cost-effective alternative to traditional etching and silver-based inks, especially for double-sided and high-density boards.
Wearables and flexible devices: Stretchability and low-temp processing make copper ideal for smart textiles, health sensors, and flexible electronics.
Addressing Remaining Hurdles
Copper inks aren’t a silver bullet (pun intended). Long-term stability in harsh environments still needs attention. Protective coatings and encapsulation are key strategies.
Process optimization is also critical: sintering conditions, ink formulation, and substrate compatibility must be fine-tuned for each application.
Fortunately, the pace of innovation is fast:
New processes, such as Photonic sintering, are enabling rapid curing of copper inks without damaging sensitive substrates.
Advances in nanoparticle chemistry are delivering inks with both high conductivity and long-term durability.
Material Informatics are being applied to reduce the lengthy iteration process of optimizing materials and formulations.
What’s Next?
The move from silver to copper isn’t just a material substitution—it’s a mindset shift. As copper inks continue to mature, expect to see:
Wider adoption across consumer, industrial, and medical electronics
New device designs that leverage copper’s unique properties
Further cost and environmental gains
More innovation in flexible, stretchable, and 3D-printed electronics
Bottom line: Copper inks aren’t a backup plan anymore. They’re leading the next phase of growth in printed electronics.
Silver’s supply risks aren’t going away. The market is already shifting. If you’re still on the fence, now’s the time to view copper inks not just as an alternative—but as a strategic advantage.
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