Enabling circularity of copper through nanoscale impurity control

Copper (Cu) is essential to the electrification of society, yet primary Cu ores contain less than 1% metal, making mining insufficient to meet the demands of the clean energy transition. Recycling offers a viable alternative, reducing CO₂ emissions by up to 65%, but conductivity losses due to scrap-related impurities hinder its application in high-performance systems. In this work, we introduce a recycling strategy for Cu recovered from electric vehicle (EV) batteries, enabling direct and circular reuse. Through nanoscale analysis, we show that by gettering impurities into nanoparticles spaced approximately 40 nm apart, they become effectively “invisible” to conduction electrons. This self-cleaning mechanism maintains both electrical conductivity and mechanical integrity, turning detrimental impurities into functional alloying elements and facilitating the sustainable reuse of Cu.