Vehicle lightweighting, once very much in vogue, has slipped out
of the headlines in the past few years as the environmental
benefits of lightweighting were outweighed by the rush to
electrify. Now with the growth rate of electric vehicle (EV) sales
slowing, lightweighting is once again part of the discussion.
The transition toward lightweighting is fueled by the adoption of
advanced materials, particularly polymers and aluminum. Russ
Balzer, technical director at World Auto Steel, highlighted that
“sustainability has emerged as a critical element of that decision
process,” underscoring the importance of life cycle impacts and
recyclability in material selection.
Aluminum, renowned for being light, can cut vehicle weight by 50%.
But, regulatory bodies, especially in the EU, are intensifying
scrutiny over the environmental impacts of vehicle manufacturing
materials. Recent regulations require manufacturers to assess
emissions on a life cycle basis, incentivizing a focus on
sustainable materials and emphasizing transparency in
lightweighting efforts. On a life cycle basis, aluminum’s
environment contribution is very sensitive to how carbon-intensive
the energy used in the upstream manufacturing processes is.
The competitive landscape is increasingly complicated by the rise
of Chinese electric vehicles, which significantly influence global
aluminum production. This situation has resulted in market
overcapacity and heightened price pressures. Michael Hahne, vice
president of automotive at Novelis Europe, warned that this influx
is expected to favor local sourcing and spike aluminum demand,
particularly for battery boxes. Additionally, the EU’s antisubsidy
investigation into Chinese EVs may lead to tariff adjustments,
disrupting established supply chains and influencing aluminum
procurement strategies.
Collaboration between material suppliers and automotive
manufacturers is vital for developing materials that meet evolving
industry demands. A representative from polymer-maker Covestro
anticipates increased recycled polymeric materials in vehicle
construction, highlighting their significance for sustainability.
Hydro, an aluminum and renewable energy company, emphasized working
closely with original equipment manufacturers to optimize product
design for weight reduction. “Hydro is working individually with
the OEMs to optimize the design and performance of the products,” a
Hydro representative stated. This collaborative approach is
essential as manufacturers strive to balance weight reduction with
safety performance. Developing specialized aluminum alloys
represents one strategy to achieve this balance while maintaining
safety standards.
Despite the benefits of lightweighting, challenges such as high
production costs and recycling complexities persist in the
transition from traditional materials. Carbon fiber, for example,
offers advantages in weight and stiffness, but its production costs
and limited recycling options are problematic. The automotive
sector must also address the need for high-quality recycled
aluminum, with innovations in sorting technologies, such as
laser-induced breakdown spectroscopy, becoming crucial for
improving recovery rates and material purity.
Looking ahead, the automotive industry is set to maintain its focus
on lightweighting to achieve sustainability goals. The rise of EVs
increases overall vehicle weight due to additional components. “The
shift toward new energy propulsion in the automotive industry is
accompanied by an increase in vehicle weight due to additional
components in electric vehicles, such as batteries,” an executive
of engineering materials company Envalior noted. The integration of
smart materials and composite technologies will be pivotal, as
polymers and plastic-metal hybrids enhance design flexibility,
enabling innovative shapes that reduce weight while preserving
mechanical properties.
As regulatory pressures escalate and consumer expectations shift
toward sustainability, those who adapt will not only gain a
competitive edge, but propel the industry to a more sustainable
future. For suppliers, this means innovating materials that meet
evolving standards. Meanwhile, OEMs must embrace these changes to
remain relevant in a dynamic market. The future of automotive
design hinges on balancing performance, safety and environmental
responsibility — a challenge that, if met, could redefine the
industry’s landscape.
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This article was published by S&P Global Mobility and not by S&P Global Ratings, which is a separately managed division of S&P Global.
