What materials are cars made out of?

Modern cars are built primarily from steel and aluminum, backed by plastics and composites, glass, rubber, and copper; electric vehicles add substantial battery materials such as lithium-ion chemistries (including LFP and NMC) and graphite. The exact mix varies by vehicle type and brand, but most passenger cars combine metals for strength, polymers for shape and comfort, and specialized materials for safety, electronics, and efficiency.

The core material mix

At a high level, automakers blend categories of materials to deliver safety, performance, cost control, and sustainability. Here are the major groups that make up a typical car.

• Metals (steel, aluminum, magnesium, stainless steel, copper, zinc)
• Plastics and polymers (PP, ABS, PC, PA/nylon, PU foams, PVC, TPO)
• Composites (glass-fiber SMC, carbon fiber, natural fiber-reinforced plastics)
• Glass and ceramics (laminated and tempered safety glass, ceramic coatings)
• Elastomers and textiles (rubber for tires and seals; fabrics, leather, synthetics)
• Electronics and wiring metals (copper, aluminum; rare-earth magnet materials in motors)
• Coatings, sealants, and adhesives (e-coat, primers, sealers, structural epoxies)
• Battery materials in EVs (cathode/anode materials, electrolytes, separators, enclosures)

Together, these categories create a balanced structure: metals carry loads and protect occupants, polymers and composites deliver design flexibility and weight savings, and specialized materials enable safety systems and electrification.

Metals: the skeleton and skin

Metals remain the backbone of automotive structure and safety. Here’s where key metals are used and why.

• Steels (mild to ultra-high-strength): Dominant in most bodies-in-white and crash structures. Automakers use advanced high-strength steels (AHSS) and press-hardened boron steels in pillars, sills, and rails to absorb crash energy while keeping weight moderate. Most body steel panels are zinc-coated (galvanized) for corrosion resistance.
• Aluminum: Widely used in hoods, doors, fenders, suspension components, motor housings, and subframes. Automakers increasingly employ large die castings (“gigacastings”) for front/rear underbodies to reduce parts count and weight. Series 5xxx/6xxx aluminum alloys are common for sheets; cast aluminum dominates complex parts.
• Stainless steel: Used historically in exhaust systems and trim; niche use in body panels. One high-profile example is the Tesla Cybertruck’s cold-rolled stainless exoskeleton, a notable exception to industry norms.
• Magnesium: Appears in lightweight cast parts such as dashboard cross-car beams, steering wheels, and brackets. It offers excellent weight savings but is used selectively due to cost and corrosion management.
• Copper: Critical for wiring harnesses, connectors, motors, inverters, and busbars. Electric vehicles use significantly more copper than gasoline cars because of high-voltage cabling and motor windings.
• Zinc (and zinc alloys): Primarily for corrosion protection (galvanizing steel) and small die-cast components. Zinc coatings extend body life in harsh environments.
• Other metals: Small amounts of tin, lead (largely phased down), nickel, and titanium appear in coatings, electronics, fasteners, and specialized components.

In practice, automakers mix metals to hit strength, crash performance, and weight targets while managing cost and manufacturability at high volumes.

Plastics, foams, and composites: shaping interiors and aerodynamics

Polymers and composites offer light weight, intricate shapes, and pleasant surfaces—vital for interiors, exterior trim, and underbody systems.

• Polypropylene (PP): Used for bumper fascias, interior trim, and battery covers. It’s light, impact-resistant, and cost-effective.
• ABS and PC/ABS: Common in interior panels, instrument clusters, and structural trim because they mold precisely and finish well.
• Polycarbonate (PC) and PMMA: PC is used for headlamp lenses (with hardcoats); PMMA often appears in tail lamps for clarity and UV resistance.
• Nylons (PA 6/6, PA 6, PPA): Employed in under-hood components, connectors, and thermal management parts thanks to heat and chemical resistance.
• Polyurethanes (PU): Seat cushions, headliners, and acoustic foams rely on PU for comfort and noise reduction.
• PVC, TPO, TPV: Soft skins, door seals, and weatherstrips balance durability with tactile quality and sealing performance.
• Composites: Glass-fiber-reinforced plastics (e.g., SMC) form body panels, spring elements, and structural inserts. Carbon fiber-reinforced polymer (CFRP) appears in performance parts (roofs, tubs) where high stiffness-to-weight is critical.
• Natural-fiber composites: Flax, hemp, or kenaf fibers in door cards and trims reduce weight and improve sustainability with acceptable stiffness.
• Adhesives and sealants: Structural epoxies and polyurethanes bond mixed materials (steel-aluminum-composite), improve rigidity, and seal joints against water and corrosion.

These materials help cut mass without sacrificing appearance or strength, enabling sleeker designs, quieter cabins, and better efficiency.

Glass, rubber, and other essentials

Beyond metal and plastics, several other materials are indispensable for safety, comfort, and durability.

• Automotive glass: Windshields are laminated (two layers of glass with a plastic interlayer) to prevent shattering; side and rear windows are typically tempered, with more models adopting laminated acoustic side glass for noise control. Large panoramic roofs use laminated safety glass.
• Tires and elastomers: Tires combine natural/synthetic rubber, steel belts, textile cords (nylon, aramid), carbon black, and silica. EPDM, NBR, and silicone rubbers seal doors, windows, and cooling systems; bushings isolate vibration.
• Textiles and leather: Seat fabrics and carpets commonly use polyester or recycled PET; premium models add leather or plant-based alternatives and microfibers for lighter weight and lower environmental impact.
• Paints and coatings: Bodies receive an anti-corrosion e-coat, primer, color basecoat, and clearcoat. Wheels, calipers, and some trim use powder coatings for durability.
• Noise, vibration, and harshness (NVH) materials: Butyl mats, foams, and fiber liners damp road and powertrain noise; EVs often add extra acoustic treatment because the powertrain is quieter.

These elements protect occupants from impacts and weather while shaping how a car feels and sounds on the road.

Electric vehicles: what’s different

EVs rely on many of the same materials but diverge in the propulsion system. The battery and power electronics introduce distinct chemistries and structural needs.

• Battery cathodes: Predominantly LFP (lithium iron phosphate) for cost and durability, and NMC/NCA (nickel-manganese-cobalt or nickel-cobalt-aluminum) for higher energy density. Many brands are expanding LFP in 2024–2025 for mainstream models.
• Anodes: Mainly graphite, with growing use of silicon-doped anodes to boost energy density.
• Electrolytes and separators: Lithium salts (often LiPF6) in carbonate solvents with polyolefin separators; solid-state prototypes are advancing but not yet mainstream.
• Battery enclosures and structures: Aluminum-heavy housings, steel reinforcements, and fire-resistant barriers; some platforms use structural battery packs that contribute to the car’s stiffness.
• Busbars, cabling, and motors: Thick copper busbars and high-voltage cables; motors may use rare-earth neodymium-iron-boron (NdFeB) magnets (sometimes with dysprosium for high temperature) or rare-earth-reduced/rare-earth-free designs to mitigate supply risk.
• Thermal management: Aluminum cold plates, heat exchangers, and dielectric coolants manage battery and inverter temperatures.
• Fire protection materials: Intumescent barriers, mica sheets, ceramic fiber papers, and flame-retardant foams improve battery safety.

These EV-specific materials add weight but enable high efficiency and performance; consequently, automakers offset mass with more aluminum, AHSS, composites, and advanced joining techniques.

Typical composition by weight

Conventional gasoline/diesel car

While every model differs, industry surveys and teardown studies show the following rough shares for internal-combustion passenger cars.

• Steel and iron: about 50–60%
• Aluminum: about 8–15%
• Plastics and composites: about 8–12%
• Rubber (including tires): about 5–7%
• Glass: about 2–3%
• Copper and electrical: about 1–2%
• Other metals and materials (magnesium, zinc, coatings, adhesives): about 1–3%

These ranges reflect the prevalence of steel for structure, with aluminum and polymers reducing weight where feasible.

Battery-electric vehicle

EVs shift mass toward the battery and electrical system, with compensating changes in body materials to manage overall weight and stiffness.

• Battery pack (cells plus enclosure and cooling): about 20–30%
• Steel and iron: about 35–50%
• Aluminum: about 15–25%
• Plastics and composites: about 8–12%
• Copper and electrical: about 3–5%
• Glass: about 2–3%
• Rubber (including tires): about 5–7%
• Other materials (magnets, adhesives, insulators, coatings): about 1–3%

Battery size, body design, and motor technology can move these figures significantly: long-range EVs carry heavier packs, while lightweight platforms rely more on aluminum and advanced steels.

Why these materials are chosen

Automakers juggle multiple constraints when selecting materials for each part of a car. The considerations below drive the mix you see on the road.

• Safety and crash performance: Steels (especially AHSS and press-hardened grades) manage impact forces and protect occupants.
• Weight and efficiency: Aluminum, magnesium, and composites reduce mass, improving fuel economy and EV range.
• Cost and manufacturability: Steel stampings and aluminum castings suit high-volume lines; polymers mold into complex shapes at low cost.
• Corrosion and durability: Zinc-coated steel, stainless elements, and robust coatings extend vehicle life.
• Repairability and service: Materials must weld, bond, or be replaced predictably in body shops worldwide.
• Recyclability and regulation: High recycling rates for steel and aluminum align with tightening sustainability targets; interior materials increasingly use recycled and bio-based content.

The result is a “right material, right place” strategy: each part gets the material that best meets the engineering, regulatory, and cost targets.

Trends to watch

As 2025 models roll out, several material trends are reshaping car construction and supply chains.

• Megacasting/gigacasting: Large aluminum castings replace dozens of welded parts, cutting complexity and weight.
• More AHSS and press-hardened steel: Stronger grades let engineers thin panels while maintaining crash performance.
• Rising recycled content: Automakers commit to higher recycled aluminum and steel, plus recycled polymers and fabrics.
• Rare-earth reduction: New motor designs aim to cut or eliminate neodymium to diversify supply and reduce cost.
• LFP battery expansion: Cost-stable lithium iron phosphate chemistries gain share in mainstream EVs.
• Structural battery packs: Packs that contribute to body stiffness reduce parts and improve packaging.
• Natural-fiber and bio-based interiors: Door panels, trims, and seat fabrics increasingly use plant-based or recycled inputs.
• Niche stainless exoskeletons and composites: Specialty vehicles and performance models push unconventional material envelopes.
• Advanced joining: Adhesives, self-piercing rivets, laser welding, and friction stir welding support mixed-material bodies.

These shifts aim to balance cost, sustainability, and performance while accommodating the rapid growth of electrification.

Summary

Cars are multi-material machines: steel and aluminum form the structural core; plastics, foams, and composites shape interiors and aerodynamics; glass and rubber deliver safety and comfort; and electronics rely on copper and specialized alloys. Electric vehicles add substantial battery and power electronics materials, nudging the mix toward aluminum and advanced steels to control weight. As regulations, costs, and technologies evolve, so does the recipe—always blending the right materials in the right places.

Is a car made of steel?

Yes, cars are predominantly made of steel, particularly for structural components like the chassis and body, due to its strength, durability, safety, and affordability. However, modern vehicles also incorporate other materials such as aluminum, plastics, glass, and rubber in different parts, balancing weight, fuel efficiency, and cost with the essential safety and structural integrity provided by steel.
 
Why Steel is Crucial

• Safety: Steel’s inherent capacity to absorb and diffuse crash energy makes it ideal for vehicle frames and body components, protecting passengers during collisions. 
• Structural Strength: It provides the necessary strength to support a vehicle’s weight and maintain its structural integrity, preventing bending or breaking under heavy loads. 
• Durability and Longevity: Steel is a robust material that ensures vehicles are long-lasting. 
• Affordability: It is a cost-effective material compared to some other metals, making it an accessible choice for mass-produced vehicles. 
• Versatility: Various types of steel are used to meet different requirements for specific parts of the car. 

Other Common Materials
While steel forms the backbone of most cars, other materials are used for specific applications: 

• Aluminum: Opens in new tabUsed for its lightweight properties, which can help improve fuel efficiency, and for components where corrosion resistance is needed. 
• Plastics: Opens in new tabFound in dashboards, door handles, and other interior and exterior parts, offering adaptability and strength. 
• Glass: Opens in new tabEssential for windows and windshields, providing visibility and contributing to the vehicle’s overall safety and structural integrity. 
• Rubber: Opens in new tabUsed for tires and other parts that require flexibility, such as seals and mounts. 

What material is used to make cars?

Cars are primarily built using steel, plastics, and aluminum for their structures, while interiors utilize materials like cloth, vinyl, and leather for seating and trim. Rubber is used for tires and seals, and glass forms windows and windshields. Other advanced materials such as high-strength steel, carbon fiber, and magnesium are increasingly employed to enhance performance and fuel efficiency.
 
Structural Materials

• Steel: Opens in new tabA primary material for car bodies and other components due to its strength, impact absorption, and cost-effectiveness. 
• Aluminum: Opens in new tabUsed to reduce weight and improve performance, especially in high-end vehicles and certain car parts. 
• High-Strength & Ultra-High-Strength Steel: Opens in new tabAdvanced forms of steel designed to be lighter yet stronger, contributing to both safety and fuel efficiency. 
• Carbon Fiber: Opens in new tabA lightweight composite material, often used in luxury and high-performance vehicles for structural components like the unibody chassis. 
• Plastic: Opens in new tabA versatile material used extensively in interior and exterior parts, from dashboards and switches to air intake systems. 

Interior & Trim Materials

• Cloth: Opens in new tabA durable and common upholstery material, typically made from nylon or polyester, offering good resistance to heat and cold. 
• Vinyl: Opens in new tabKnown for its affordability, durability, and ease of cleaning, making it a popular choice for many car interiors. 
• Leather: Opens in new tabA premium material used for seats, steering wheels, and other interior accents, valued for its resistance to wear and tear. 
• Foam: Opens in new tabUsed for padding in seats, headliners, and sound insulation within the interior. 

Other Key Materials

• Glass: Essential for windows, windshields, and other transparent components. 
• Rubber: Used for tires, seals, and hoses due to its flexibility and durability. 
• Copper: A common material for the extensive wiring harnesses found in modern vehicles. 
• Petroleum Products: Many plastics and synthetic materials are derived from petroleum, which is also the source of fuel for internal combustion engines. 

What material is used for a car body?

Car bodies are made from a combination of materials, primarily steel, aluminum, and plastics, along with glass and rubber for other components. Steel remains a staple for its durability and cost-effectiveness, while aluminum offers a lighter, fuel-efficient alternative. Plastics are widely used for everything from dashboards to body panels, and high-performance vehicles sometimes incorporate expensive materials like carbon fiber for extreme lightness and strength.
 
Key Materials

• Steel: Opens in new tabThe most traditional and common material, steel is strong, durable, and inexpensive. Modern steel can be engineered to crumple in a controlled way to absorb impact, and it is often coated in zinc (galvanized) to prevent rust. 
• Aluminum: Opens in new tabA lighter alternative to steel, aluminum helps reduce a car’s overall weight, improving fuel efficiency. It’s a popular choice for both common vehicles and high-performance cars, with increasing use in hybrid and electric vehicles. 
• Plastic: Opens in new tabUsed in various forms, plastics are prevalent in cars today, making up a significant portion of a vehicle’s construction. They are used for interior components like dashboards and switches, but also for some body panels. 
• Carbon Fiber: Opens in new tabA lightweight and incredibly strong composite material, carbon fiber is the pinnacle of performance materials but is very costly. It is reserved for high-end sports cars and specialized racing applications, though some modern production cars use it for key structural components. 
• Glass: Opens in new tabUsed for windows and windshields. 
• Rubber: Opens in new tabFound in components like tires, but also used in other parts of the car’s body. 

Why the Mix of Materials?
The automotive industry balances several factors when choosing materials for car bodies: 

• Cost: Steel remains the cheapest option, while high-performance materials like carbon fiber are significantly more expensive. 
• Weight: Lighter materials like aluminum and carbon fiber improve fuel efficiency and performance. 
• Strength and Safety: Materials are selected and engineered to provide a strong safety cage for occupants and to absorb crash energy in predictable ways. 
• Fuel Efficiency: Reducing vehicle weight with lighter materials directly impacts fuel consumption. 
• Environmental Impact: The recyclability of materials like steel also plays a role. 

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.