Nano-engineered ultra-conductive nanocomposite copper wire

A method of forming nano-composite copper wire, comprising:

• pre-loading carbon nanotubes into at least one of a plurality of channels running a length of a cartridge;
• placing the pre-loaded cartridge in a piston chamber of a die-casting machine;
• drawing air out of the piston chamber to create a vacuum therein;
• filling the piston chamber with molten metal and soaking the pre-loaded cartridge for a predetermined time, wherein the molten metal fills cartridge channels that are not pre-loaded with carbon nanotubes;
• applying pressure via the piston to eject the carbon nanotubes and molten metal from the cartridge channels as a nano-composite mixture and inject the nano-composite mixture into a rod-shaped die cavity through a nozzle that draws down the nano-composite mixture to a first predetermined diameter that is not greater than a diameter of the die cavity;
• and
• cooling the nano-composite mixture to form a solid nano-composite rod having the first predetermined diameter, wherein the carbon nanotubes are aligned in a non-random manner in the nano-composite rod.