Batteries are at the heart of every energy storage system, and metals are essential for both battery performance and module reliability. Copper, aluminium, and lithium are the core materials used in battery cells, busbars, module frames, and enclosures.

With utility-scale, commercial, and residential ESS deployment accelerating, the demand for these metals is rising rapidly. Not only is the volume increasing, but supply chain stability has become critical. Manufacturers are paying close attention to sourcing metals and optimizing components such as:

• Lithium Battery Stainless Steel Straps

• Aluminum Busbars

• Battery Module End Plates

• Thermal Dissipation Plates

These components support safety, thermal management, and long-term reliability in products like Dagong ESS 100–144 kWh Air-Cooled ESS, 215–241 kWh Liquid-Cooled ESS, and 3.35 MWh Liquid-Cooled ESS Containers.

Which Metals Are Most Affected?

• Copper

Copper is used extensively for electrical conductivity within batteries and system wiring. Global supply constraints and rising demand in ESS projects highlight the strategic importance of copper. Adequate copper supply ensures stable current flow, module efficiency, and project scalability.

• Aluminium

Aluminium is widely used for module frames, heat-dissipation structures, and container enclosures. Lightweight and thermally efficient aluminium improves both safety and installation flexibility, making it a critical material in modern ESS systems.

• Lithium

LFP batteries, now dominant in stationary storage, require lithium compounds for cathode materials. Lithium supply stability impacts system cost, cycle life, and deployment speed.

Specialty Metals (Vanadium, Nickel, Cobalt)

Advanced storage technologies, such as vanadium flow batteries, also rely on specialty metals. Although niche today, these metals are increasingly relevant in long-duration storage systems.

How Are Battery Designs Shaping Metal Demand?

• High Deployment Scale – Large ESS projects require substantial quantities of metals for busbars, frames, and connectors.

• Thermal & Structural Optimization – Modules and containers use aluminium and copper for heat dissipation and structural integrity.

• Material Standardization – Standardized components, such as stainless steel straps, end plates, and busbars, reduce manufacturing complexity and improve reliability.

• Localized Sourcing Strategies – Global supply risks encourage manufacturers to diversify sources or vertically integrate production.

Suppliers like Dagong ESS integrate these design strategies across residential, commercial, and container-based systems, ensuring scalable and reliable deployment.

Applications: Where Metal Demand Impacts ESS Most

• Utility-Scale Storage – Containerized systems such as 5 MWh Air-Cooled ESS Containers require high amounts of copper and aluminium for structural and electrical performance.

• Commercial & Industrial Systems – Medium-scale ESS modules (100–300 kWh) depend on high-quality aluminium and copper to ensure efficiency and long-term safety.

• Residential Storage – Home systems benefit from standardised module components that reduce metal usage while improving lifespan.

Price and Supply Considerations

Metal prices, particularly for copper, aluminium, and lithium, are influenced by global supply constraints and rising ESS deployment. Battery suppliers typically provide custom pricing based on:

• Chemistry (LFP, NMC, vanadium)

• Cooling method (air vs liquid)

• Component selection (busbars, end plates, thermal plates)

• Project scale

Dagong ESS provides tailored quotations for all system sizes while optimizing metal usage for cost-efficiency and performance.

How to Select ESS Systems Amid Metal Supply Challenges

• Choose the right chemistry – LFP for stability, vanadium flow for long-duration applications.

• Assess supplier sourcing – Ensure key metals come from stable regions or vertically integrated supply chains.

• Evaluate recycling and lifecycle strategies – Reclaim copper, aluminium, and other metals where possible.

• Consider total cost of ownership – Metal efficiency via modular and standardized design reduces long-term operating costs.

Dagong ESS's ESS designs integrate these considerations, using standardised components and long-life LFP cells to ensure reliability and longevity.

How Long Do Modern ESS Batteries Last?

High-quality ESS batteries using optimized components can reliably achieve:

• 8000+ cycles (LFP systems)

• 15+ years of operational life

Standardised busbars, end plates, and thermal components contribute to safety, performance, and serviceability.

The Supplier Perspective

Leading suppliers today must combine battery expertise with material strategy. Dagong ESS offers comprehensive solutions from residential modules to multi-MWh containers, designed to optimize metal use while delivering reliable performance worldwide.