Cathode Drum Market Set for Strong Growth Amid Rising Demand for Copper Foils

Global Cathode Drum Market Set for Strong Growth Amid Rising Demand for Copper Foils

The cathode drum, a critical component in the production of copper foil, is emerging as a focal point in the rapidly expanding electric vehicle (EV), renewable energy, and consumer electronics sectors. As the backbone of the copper foil manufacturing process, the cathode drum plays a pivotal role in determining the quality, uniformity, and mechanical properties of copper foils used in both printed circuit boards (PCB) and lithium-ion batteries.
          

Copper Foil Manufacturing and the Role of Cathode Drums

Copper foil production primarily involves four stages: copper dissolution, foil deposition, post-treatment, and slitting. In the dissolution stage, copper is converted into a copper sulfate solution using sulfuric acid and deionized water, forming the electrolysis bath essential for foil deposition. During the foil deposition process, the cathode drum—usually made of titanium—is central to copper ion reduction. Copper ions in the electrolyte gain electrons at the cathode surface and crystallize into copper metal, forming a continuous foil. The surface roughness, crystallinity, and geometric uniformity of the titanium cathode drum directly affect the resulting copper foil’s grain size, thickness, and mechanical strength. High-precision cathode drums allow manufacturers to produce ultra-thin, high-strength copper foils with fine grains and excellent uniformity.

After deposition, copper foils undergo post-treatment, including acid washing and organic anti-oxidation treatments, followed by slitting and packaging according to customer requirements.

Market Segmentation and Trends

Copper foils are categorized by thickness, surface profile, and application:

• By thickness: ultra-thin (≤6μm), super-thin (6–12μm), thin (12–18μm), standard (18–70μm), and thick (>70μm).

• By surface profile: double-sided smooth, double-sided rough, double-sided coarse, single-sided rough, and very-low-profile (VLP) copper foil.

• By application: standard PCB copper foil and lithium-ion battery copper foil.

In the PCB sector, rising demand for AI servers, high-performance chips, 5G infrastructure, and automotive electronics is driving growth in high-spec copper foils. Ultra-thin carrier foils for chip packaging, ultra-low-profile foils for high-frequency circuits, and thick foils for high-current applications are seeing increased adoption. The global PCB market is projected to reach USD 73.565 billion in 2024, growing at 5.8% year-on-year, with an estimated USD 90.4 billion by 2028. China is expected to mirror this trend, reaching a PCB market value of approximately USD 46.18 billion by 2028.

In the lithium-ion battery segment, copper foils are evolving toward ultra-thin, high-strength, and high-ductility products to meet the requirements of high-capacity, thin, and high-density batteries. Leading Chinese battery manufacturers, including CATL, EVE Energy, CALB, and Hive Energy, are investing in 4–5μm ultra-thin copper foils, a shift from the current mainstream 6–8μm products. Global lithium-ion battery shipments are expected to reach 1,474 GWh in 2024, a 26.4% increase over the previous year, and grow to 2,564 GWh by 2027 at a CAGR of 20.27%.

Technological Differences Between Japanese and Chinese Cathode Drums

Japanese manufacturers are leading in cathode drum crystallinity, achieving levels above 12, while Chinese producers typically range from 7 to 12. Japanese drums often use alloyed titanium, which offers longer resistance to oxidation and requires less frequent polishing and maintenance. In terms of manufacturing technology, Japanese producers mainly employ welded titanium plates that are later polished, ensuring uniform crystal structures across the drum. Chinese manufacturers commonly use a spinning process to form seamless titanium cylinders, reducing welding issues but posing challenges in crystal structure consistency due to the mechanical deformation of the material during spinning.

Global Market Outlook

The global cathode drum market is projected to reach USD 480 million in 2025, growing at a CAGR of 8.5% through 2030. Growth is largely driven by rising copper foil demand in EVs, renewable energy systems, consumer electronics, and the increasing production of high-performance PCBs and lithium-ion batteries.

Opportunities and Challenges

Opportunities in the cathode drum market stem from the surge in high-performance electronics, the rapid adoption of EVs, and advancements in battery technologies. Manufacturers that can produce cathode drums with finer grain structures, high uniformity, and superior mechanical properties are likely to gain a competitive edge.

Challenges include the technological gap between established Japanese producers and emerging Chinese manufacturers, particularly in achieving consistent drum crystallinity and oxidation resistance. Additionally, the market requires continuous innovation to meet the demands of ultra-thin, high-strength copper foils, especially for next-generation lithium-ion batteries and 5G-enabled electronics.