What Material Is Used to Make Cars

Cars are made from a mix of metals (primarily steel and aluminum), plastics and composites, glass, rubber, and—especially in electric vehicles—battery and motor materials such as copper, lithium, and rare earth magnets. Automakers combine these materials to balance safety, weight, performance, cost, sustainability, and manufacturability, with newer models increasingly using advanced high-strength steels, lightweight alloys, structural adhesives, and recycled content.

The core metals that shape the car

Metals form the backbone of the vehicle’s structure and critical systems. Engineers select alloys for their strength-to-weight advantages, corrosion resistance, crash performance, and cost—often in multi-material bodies that mix steels and aluminum.

• Steel and advanced high-strength steel (AHSS/UHSS/PHS): The dominant material in most body-in-white structures, pillars, rails, and crash zones; typically galvanized for corrosion resistance and formed by stamping or hot-pressing.
• Aluminum alloys (6xxx sheet, high-pressure die-cast Al-Si-Mg, and extrusions): Used for closures (hoods, doors), chassis parts, and increasingly large castings and battery housings to cut weight while maintaining stiffness.
• Cast iron and steel for powertrain and brakes: Gray iron or compacted graphite iron for traditional engine blocks and brake rotors; performance models may adopt carbon-ceramic rotors.
• Magnesium alloys: Lightweight die-cast components for seat frames, instrument panel supports, or housings; used sparingly due to cost and corrosion/flammability considerations.
• Copper: Wiring harnesses, motors, busbars, and power electronics interconnects; EVs use several times more copper than comparable ICE vehicles.
• Stainless steel: Exhaust systems, fasteners, trim, and—on a few models—exterior panels where corrosion resistance and surface hardness are prioritized.

Together, these metals deliver the structural integrity and electrical conductivity vehicles require, with design teams trading off cost, mass, and manufacturing routes for each application.

Plastics, composites, and elastomers

Polymer-based materials reduce weight, enable complex shapes, improve durability and NVH (noise, vibration, harshness), and cut cost for high-volume parts, while composites add stiffness and strength where needed.

• Thermoplastics: Polypropylene (PP) for bumpers and interior trim; ABS/PC for consoles and bezels; polyamides (PA/nylon) for under-hood components; PBT and POM for connectors and gears; PVC for seals and coatings; PMMA/PC for lighting lenses.
• Foams: Polyurethane (PU) for seats; expanded polypropylene (EPP) and expanded polystyrene (EPS) as energy absorbers in bumpers and headliners.
• Fiber-reinforced composites: Glass fiber-reinforced polymer (GFRP) panels and springs; carbon fiber-reinforced polymer (CFRP) for high-performance roofs, tubs, and structural reinforcements.
• Adhesives and sealants: Structural epoxies, acrylics, and polyurethanes used with spot welding and mechanical fasteners to join mixed materials and improve crash performance.
• Rubber and elastomers: Tires (natural and synthetic rubber blends with steel/textile cords), EPDM weatherstrips, NBR/FKM fuel and high-temperature seals, and silicone for gaskets and wiring protection.

These materials unlock design freedom and weight savings, improving efficiency and comfort without sacrificing durability or safety.

Glass, ceramics, and protective coatings

Transparency, visibility, and environmental durability depend on engineered glass, ceramic components, and multi-layer protective coatings throughout the vehicle.

• Automotive glass: Laminated windshields for safety and acoustics; tempered side and rear glass; laminated panoramic roofs on many models for UV and sound control.
• Ceramics: Cordierite or metallic substrates in catalytic converters; alumina in spark plug insulators and sensor ceramics; carbon-ceramic brake discs in high-performance applications.
• Coatings and treatments: Zinc-coated (galvanized) steels, electrocoat (e-coat) primers, basecoat/clearcoat paint systems, powder-coated wheels, and underbody corrosion protections.

Beyond appearance, these layers and components extend vehicle life, enhance safety, and protect against heat, corrosion, debris, and UV exposure.

Materials unique to electric vehicles

EVs add specialized materials for energy storage, power delivery, and thermal management, even as they share many conventional materials with ICE vehicles.

• Battery cells and packs: Cathode materials such as NMC/NCA (nickel, manganese, cobalt) and LFP (lithium iron phosphate); anodes of graphite with rising silicon content; electrolytes (e.g., LiPF6 in carbonate solvents); separators (PP/PE); current collectors (aluminum for cathodes, copper for anodes); casings in aluminum, steel, or laminated foil; pack structures largely aluminum with fire barriers, insulators, and potting compounds.
• Motors and magnets: Copper windings and steel laminations; many traction motors use NdFeB permanent magnets (neodymium, praseodymium, with reduced dysprosium/terbium), while others use induction or reluctance designs to avoid rare earths.
• Power electronics: Silicon carbide (SiC) and silicon devices in inverters and onboard chargers; ceramic substrates (aluminum nitride or silicon nitride) with copper metallization for thermal performance.
• High-voltage conductors and insulation: Copper or aluminum busbars and orange HV cables with cross-linked polyethylene (XLPE), polyimide, PTFE, or PEEK insulation.
• Thermal management: Glycol-water coolants, aluminum cold plates, thermal interface materials, foils, aerogels, and intumescent barriers for thermal runaway protection.

These EV-specific materials prioritize energy density, efficiency, and safety while managing heat and high voltages under demanding operating conditions.

Sustainable and recycled materials

As regulations tighten and buyers prioritize sustainability, automakers are increasing recycled content and bio-based materials while planning for end-of-life recovery.

• Recycled metals: High recycled content in aluminum sheet and castings; significant scrap utilization in steel production; closed-loop recycling in stamping and casting operations.
• Recycled and bio-based polymers: Interior fabrics from recycled PET; recycled PP for liners and trim; natural fibers (hemp, kenaf) in door cards; bio-based foams and coatings to cut fossil inputs.
• Battery circularity: Recovery of lithium, nickel, cobalt, and copper through hydrometallurgical and pyrometallurgical recycling; growing LFP adoption reduces reliance on cobalt and nickel.
• Regulatory drivers: EU end-of-life vehicle rules target high reuse/recycling and recovery rates by mass; new battery regulations in major markets require lifecycle disclosures, recycled content, and digital “battery passports” this decade.

These initiatives reduce lifecycle emissions and material risks, with design-for-recycling and traceability becoming standard across new programs.

Where each material typically goes

Material shares vary by segment and powertrain, but the following ranges reflect common practices in modern vehicles.

• ICE vehicles (approximate ranges by mass): 50–65% steel/iron; 10–20% aluminum; 10–15% plastics/composites; 3–5% copper and other nonferrous metals; 3–5% glass; 5–8% rubber and miscellaneous.
• EVs (approximate ranges by mass): 35–55% steels/irons; 15–30% aluminum (including pack structures and castings); 10–15% plastics/composites; 5–10% copper; 3–5% glass; battery cells and modules often account for 15–30% of total vehicle mass depending on range.
• Part-level patterns: Bodies mix AHSS with aluminum closures; chassis combine steel stampings with aluminum control arms; interiors rely on PP/ABS/PC and PU foam; glazing is laminated/tempered glass; tires blend rubber, steel, and textiles.

Actual choices depend on cost targets, performance goals, manufacturing footprint, and regional supply chains, leading to notable variation among brands and models.

How automakers choose and join materials

Material selection weighs crash energy management, stiffness, corrosion, repairability, sustainability, and cost. Joining methods are tailored to material stacks: spot and laser welding for steels; MIG/TIG and friction-stir welding for aluminum; self-piercing rivets, flow-drill screws, and structural adhesives for mixed materials; and overmolding or insert molding for polymers. The result is a multi-material architecture optimized for safety and efficiency.

Quick facts

These snapshots highlight current trends shaping what cars are made of in 2024–2025.

• Advanced high-strength steels continue to gain share for crash-critical parts while lowering mass versus conventional grades.
• Aluminum usage is rising in closures, chassis, and large die castings to offset the weight of safety features and batteries.
• EVs use significantly more copper than ICE vehicles due to motors, inverters, and high-voltage cabling.
• LFP batteries have grown rapidly, especially in mass-market EVs, reducing dependence on cobalt and nickel.
• Structural adhesives are now routine, enabling strong, corrosion-resistant joints across mixed materials.
• Interior sustainability is accelerating, with recycled PET fabrics and bio-based composites entering mainstream models.

Taken together, these shifts reflect a steady move toward lighter, safer, and more sustainable vehicles without compromising performance.

Summary

Modern cars are multi-material products: steels and aluminum for structure, copper for electrics, polymers and composites for lightweighting and design freedom, glass and ceramics for safety and durability, and in EVs, specialized battery and motor materials. Manufacturers blend these to meet safety, efficiency, cost, and sustainability targets—an evolving recipe that increasingly features advanced alloys, smarter joining, and recycled content.

Are cars metal or plastic?

Cars are made from a combination of plastic, metal, rubber, glass, and other materials, with steel being the most common and dominant material for the vehicle’s frame and body, while plastic is used extensively for many smaller components to save weight and reduce costs. 
Metals in a Car

• Steel Opens in new tabis the primary material for the chassis, body, engine parts, and suspension components due to its strength, durability, and cost-effectiveness. 
• Aluminum Opens in new tabis used in some body panels, like hoods, to reduce weight for better fuel efficiency. 
• Magnesium, copper, and titanium Opens in new tabare also used for specific components, offering benefits like light weight, electrical conductivity, or corrosion resistance. 

Plastics in a Car

• Plastics: are used in large quantities for interior components such as airbags, switches, and dashboard parts. 
• They also make up many exterior elements, including the front and rear fascias (bumpers). 
• The use of plastic contributes to weight savings, leading to better fuel economy and lower production costs. 

Other Materials

• Rubber: is used for tires, seals, and hoses. 
• Glass: is used for windows and mirrors. 
• More advanced materials like carbon fiber and fiberglass are used in some specialized or high-performance vehicles, like the Chevrolet Corvette, for their exceptional strength-to-weight ratios. 

What material are car bodies made of?

Car bodies are most commonly made of steel due to its strength, durability, and cost-effectiveness, but other materials like aluminum, plastics, composites, and carbon fiber are used to reduce weight, improve fuel efficiency, or enhance performance. The choice of material depends on a balance between cost, safety, durability, and environmental considerations, with a trend towards lighter metals and advanced composites in modern vehicle design.
 
Common Car Body Materials

• Steel: Opens in new tabThe most traditional and widely used material, steel is strong, durable, and relatively inexpensive to produce and work with. 
• Aluminum: Opens in new tabA popular alternative, aluminum is significantly lighter than steel, which helps to improve fuel efficiency and reduce emissions. 
• Plastics and Composites: Opens in new tabThese materials are very lightweight, flexible, and corrosion-resistant, making them suitable for non-structural parts like fascias or for certain applications in sports cars. 
• Carbon Fiber: Opens in new tabA high-performance material used in exotic and race cars, carbon fiber is extremely strong and lightweight but comes at a very high cost. 

Why Material Choice Matters

• Cost: Steel remains the most affordable material for mass-produced vehicles, while aluminum and carbon fiber are more expensive. 
• Weight and Fuel Efficiency: Lighter materials like aluminum and carbon fiber help reduce a car’s overall weight, leading to better fuel economy and performance. 
• Durability and Strength: Steel offers excellent strength and durability, while composites and carbon fiber provide high strength-to-weight ratios but may be less tough than metal. 
• Manufacturing: Steel is easy to form and repair, whereas aluminum and carbon fiber can present greater manufacturing challenges. 
• Safety and Performance: Material selection is a key factor in meeting safety standards and achieving desired vehicle performance characteristics. 

Trends in Car Body Materials

• There is a continuous effort to find materials that offer a better balance of cost, weight, safety, and performance. 
• Advanced high-strength steels offer a better combination of strength and lightness than traditional steels. 
• The increasing demand for fuel-efficient vehicles is driving greater use of lighter materials like aluminum and advanced composites. 

What is the main material used to make cars?

Steel, rubber, plastics, and aluminum are the four most common commodities found in cars. The auto industry relies heavily on petroleum products, not just for gasoline for autos with internal combustion engines (ICE), but for synthesizing plastics and other synthetic materials.

What are the raw materials used in cars?

The four main materials are steel, aluminium, plastic, and glass. These materials are used in different proportions depending on the type of vehicle, its purpose, and the manufacturer’s preferences. Steel is the most commonly used material in the automotive industry, accounting for around 60% of the vehicle’s weight.