What most cars are made of now

Most cars today are still primarily made of steel—especially advanced high-strength steel—augmented by aluminum, plastics and polymers, glass, and rubber; electric vehicles tend to use more aluminum for weight savings while retaining significant steel in the safety cell and chassis. In practice, automakers now build multi-material bodies that balance cost, crash safety, manufacturability, and efficiency, with the exact mix varying by vehicle class and drivetrain.

The modern material mix at a glance

Over the past two decades, carmakers have shifted from mostly mild steel to a carefully engineered blend. This change reflects tougher crash standards, the push for better fuel economy and EV range, and stricter emissions rules across supply chains.

Where each material goes

The list below outlines the major components in a typical vehicle and the materials commonly used for each, showing how multi-material design is applied across the car.

• Body-in-white and safety cage: Advanced high-strength steels (AHSS), ultra-high-strength steel (UHSS), press-hardened steel; strategic aluminum in closures and crash zones
• Exterior panels and closures: Steel (common), aluminum (hoods, doors, trunk/liftgates; entire bodies on some models), limited composites
• Chassis and suspension: High-strength steels; aluminum control arms, subframes, knuckles for weight reduction
• Powertrain and motors: Aluminum castings (engine blocks, EV motor housings); steels for gears/shafts; copper in windings and wiring
• Battery system (EVs): Aluminum or steel enclosures and underbody protection; composite covers; nickel or iron-based lithium-ion cells (NMC/NCA or LFP chemistries)
• Interior: Plastics and polymers (PP, ABS, PVC), polyurethane foams, textiles; growing use of recycled and bio-based materials
• Glazing and lighting: Laminated and tempered glass; polycarbonate for select lenses; LED housings in plastics
• Tires and seals: Rubber compounds (natural/synthetic) with steel cords and textile reinforcements
• Adhesives and sealants: Structural adhesives, foams, and sealers used extensively for stiffness, noise reduction, and corrosion control

While the exact content varies by model, this component-level view shows why most vehicles remain steel-led with targeted use of aluminum and polymers where they add the most value.

Typical composition by weight

Because vehicles differ widely, percentages vary. The ranges below reflect mainstream passenger cars and crossovers, with EVs shown separately due to their batteries and castings.

• Internal-combustion vehicles: roughly 50–65% ferrous metals (mostly steels, some iron), 8–15% aluminum, 10–15% plastics/polymers, 5–10% rubber, 2–4% glass, 1–2% copper and other nonferrous metals
• Battery-electric vehicles: roughly 40–55% ferrous metals, 15–30% aluminum (higher for models using large castings and battery enclosures), 10–15% plastics/polymers, 5–10% rubber, 2–4% glass, 2–5% copper; plus 300–600 kg of battery cells depending on pack size

Most mass-market vehicles remain steel-dominant by weight, while EVs shift more mass to aluminum and copper, but not enough to displace steel as the core structural material in the segment overall.

Why the mix looks this way

Safety, cost, manufacturability, and environmental performance drive material choice. AHSS enables thinner sections with higher crash energy absorption; aluminum trims weight in closures, subframes, and battery enclosures; polymers help with design flexibility, cost, and acoustic insulation—all combined with adhesives and spot welds to tune stiffness and crash response.

Differences between mainstream and premium models

The following points highlight how material strategies differ by market position and manufacturing approach.

• Mass-market vehicles: Predominantly steel structures with selective aluminum panels and components to manage cost
• Premium/sport models: More aluminum-intensive bodies, larger castings, and selective carbon-fiber or glass-fiber composites
• Pickup trucks and large SUVs: Mix of steel frames/bodies with significant aluminum panels (e.g., aluminum body panels on popular full-size pickups)
• EV innovators: Use of large “gigacast” aluminum front/rear structures on some models; steel floor structures remain common for crash and battery protection

These differences reflect trade-offs between capital investment, repairability, weight targets, and brand priorities on performance or efficiency.

EVs and the rise of aluminum and castings

Electric vehicles favor aluminum for battery enclosures and large cast structures to reduce weight and parts count. Copper content rises for high-voltage cabling and motors. Still, steel remains central in the passenger safety cell and underbody protection to meet crash and intrusion standards.

Battery chemistry and its impact on materials

Battery cell choice does not change body materials, but it influences pack design and protection needs.

• NMC/NCA chemistries: Higher energy density; often paired with robust thermal management and aluminum-heavy enclosures
• LFP chemistries: Lower energy density but improved cycle life and cost; pack formats can allow structural integration with steel or aluminum base structures
• Structural packs: Increasing use of adhesives and castings to integrate the pack into the body floor for stiffness

As pack designs evolve, enclosure materials toggle between aluminum, steel, and composites depending on cost, thermal, and crash targets.

Sustainability and recyclability

Automakers are tightening material carbon footprints alongside tailpipe emissions. That affects both what a car is made of and how those materials are produced.

Low-CO2 pathways now entering production

These developments are shaping the material mix and sourcing decisions in current and upcoming models.

• “Green steel”: Steel made via electric arc furnaces using scrap and, increasingly, hydrogen-based direct reduced iron to cut CO2
• Closed-loop aluminum: High recycled content and in-plant scrap return to mills for new sheet and castings
• Recycled polymers: Post-consumer and post-industrial plastics in interior trims, underhood components, and wheel arch liners
• Bio-based and natural fibers: Kenaf, hemp, flax composites and recycled textiles for interior panels and seat fabrics
• Responsible copper and battery materials: Traceability programs for nickel, lithium, and cobalt; growing LFP adoption reduces reliance on cobalt and nickel

These changes don’t eliminate steel or aluminum; they reduce their lifecycle emissions and increase recycled content across the vehicle bill of materials.

Repair, safety, and manufacturing considerations

Mixing materials demands modern joining (adhesives, self-piercing rivets, laser welding), corrosion control between dissimilar metals, and specialized repair procedures. Regulators continue to push for improved occupant and pedestrian protection, reinforcing the central role of high-strength steels and engineered crumple zones even as lightweighting advances.

Bottom line

Most cars on the road today are still made mostly of steel—now in advanced grades—backed by aluminum parts, extensive plastics, and specialized materials for glazing, tires, wiring, and batteries. EVs tip the balance toward more aluminum and copper but retain steel as the backbone of safety and structure.

Summary

Modern cars are multi-material products: steel remains the primary structural material; aluminum is widely used for weight-critical parts and EV enclosures; plastics shape interiors and aerodynamics; copper supports electrification; and glass and rubber complete core functions. The trend is toward lighter, stronger, and lower-carbon materials rather than a single replacement for steel across the fleet.

Are any cars 100% US made?

No car sold in the U.S. is entirely made in America using only parts made in America. Not one single vehicle. Many vehicles from American companies, like Ford, Chevy, and Stellantis (which owns brands like Jeep and Ram), are assembled in Canada and Mexico.

Are any cars made of steel anymore?

Yes, cars are still made of steel, with steel making up about 54% of the average vehicle’s mass, though modern vehicles also incorporate other materials like aluminum, plastic, and carbon fiber for various parts. Modern cars utilize advanced steel, such as Ultra-High-Strength Steel (AHSS), in body structures to achieve lighter weight, enhanced safety, and better fuel efficiency. 
Steel in Modern Cars

• Structural component: Steel is a primary material for vehicle bodies and chassis due to its strength, durability, and cost-effectiveness compared to other metals. 
• Safety: The use of advanced steel grades helps create a vehicle’s unibody structure, which is crucial for absorbing crash energy and providing rigidity. 
• Versatility: Steel can be easily manufactured and formed into complex shapes, but its properties can vary depending on the specific grade, like mild steel and high-strength steel. 

Other Materials

• Aluminum: Opens in new tabUsed for parts like hoods and rear deck lids to reduce weight, though it is more difficult to repair and has limited memory properties. 
• Plastic: Opens in new tabA common material for various parts, including front and rear fascias, bumpers, and interior components, often chosen for its low cost and contribution to fuel efficiency. 
• Carbon Fiber: Opens in new tabAn exceptionally strong and lightweight composite material but is generally too expensive for mass-market cars, typically reserved for high-end vehicles and racing. 

Why the Mix of Materials?
Car manufacturers use a mix of materials to balance cost, weight, safety, fuel efficiency, and manufacturing ease for different parts of the vehicle.

What material are cars made of today?

Steel is produced from iron ore and is traditionally widely used in auto manufacturing. On average, 900 kilograms of steel are used in every car. Steel is used to construct a car’s chassis and body, including the roof, body, door panels, and the beams between doors. Steel is also used in mufflers and exhaust pipes.

What are cars made from now?

Modern cars are complex constructions of diverse, advanced materials including steel, aluminum, plastics, glass, rubber, and carbon fiber, selected for factors like weight reduction, fuel efficiency, and safety. While steel remains a major component for the body and frame due to its strength and cost-effectiveness, the use of lightweight metals like aluminum, high-strength steels, and advanced materials such as carbon fiber and magnesium has increased to meet efficiency mandates and improve performance. Plastics are also extensively used, making up a significant portion of the vehicle’s parts, from the interior components to various exterior elements. 
Common Materials

• Steel: A primary material for the car’s chassis, body, frame, and suspension components, it provides strength and is relatively inexpensive. 
• Aluminum: Used for wheels, engine blocks, and other parts to reduce weight, improving fuel economy. 
• Plastics: Used extensively in the interior (dashboards, handles) and for exterior components like front and rear fascias. 
• Glass: For windows and windshields, essential for visibility. 
• Rubber: Used for tires and various seals, hoses, and mounts. 

Advanced Materials

• High-Strength and Ultra-High-Strength Steels: Opens in new tabLighter and stronger than traditional steel, these are used in areas requiring maximum protection. 
• Carbon Fiber: Opens in new tabA lightweight and incredibly strong composite material used in some performance and luxury vehicles. 
• Magnesium: Opens in new tabAlso used for its light weight in various components. 
• Boron: Opens in new tabAn extremely hard material used in some ultra-high-strength steel applications for safety. 

Factors Influencing Material Choice

• Weight Reduction: Lighter materials like aluminum and carbon fiber are critical for improving fuel economy and reducing emissions. 
• Safety: Materials like high-strength steels and boron are crucial for absorbing impact and protecting occupants in a collision. 
• Cost: The cost of materials and their ease of manufacturing influence their use in different parts of the vehicle. 
• Durability and Corrosion Resistance: The choice of material also depends on its ability to withstand wear, corrosion, and other environmental factors. 
• Sustainability: Automakers are increasingly exploring sustainable materials, such as those derived from natural fibers or plants, to reduce the environmental impact of vehicle manufacturing.