What materials are used to make a car?

Modern cars are built from a mix of metals (primarily steel and aluminum), polymers and elastomers (plastics, foams, and rubber), glass, composites, and a growing array of electronic materials and critical minerals; electric vehicles add large lithium‑ion battery systems and powerful magnets or alternative motor materials.

Core structural materials

The vehicle’s body, chassis, and crash structures rely on metals and composites engineered for strength, stiffness, corrosion resistance, and manufacturability. Below is a look at the key materials shaping the “body-in-white” and supporting structures.

• Steel and advanced high-strength steel (AHSS): Conventional mild steels alongside AHSS, ultra-high-strength, and press-hardened boron steels (e.g., 22MnB5) for crash-critical zones, pillars, and rockers.
• Aluminum alloys: 5xxx/6xxx series for hoods, doors, closures, body panels, battery enclosures, and increasingly large castings (“gigacastings”) that consolidate chassis/body parts.
• Magnesium alloys: Lightweight components such as steering wheels, seat frames, instrument panel supports, and certain brackets.
• Composites: Glass-fiber reinforced plastics for body panels and structural inserts; carbon fiber composites in performance vehicles and select roof, hood, or reinforcement parts.
• Glass: Laminated safety glass (polyvinyl butyral, PVB, interlayer) for windshields; tempered glass for side and rear windows, and panoramic roofs.
• Adhesives, sealants, and coatings: Structural epoxies and polyurethanes for multi-material joining; seam sealers; e‑coat, primers, color coats, and clear coats for corrosion and appearance.

Together, these materials balance weight, strength, cost, and repairability, with multi-material joining (spot welding, laser welding, riveting, bonding) enabling optimized structures.

Powertrain and drivetrain materials

Internal combustion vehicles

In gasoline and diesel models, high-temperature metals and catalysts dominate the engine, transmission, and exhaust systems.

• Engine blocks and heads: Cast iron (durable, cost-effective) or aluminum alloys (lighter, better heat dissipation).
• Transmission and driveline: Alloy steels for gears, shafts, and differentials; aluminum housings for weight savings.
• Exhaust and emissions control: Stainless steels and Inconel in hot zones; catalytic converters using platinum-group metals (platinum, palladium, rhodium).
• Fuel and air systems: Engineering polymers (e.g., PA, POM, PPS) for fuel rails, intake manifolds, and connectors; rubber and fluoropolymer hoses and seals.

These selections withstand heat, vibration, and chemical exposure while meeting emissions and durability targets.

Electric and hybrid vehicles

EVs and hybrids replace or supplement engines with battery packs, electric motors, and power electronics that require specialized metals, ceramics, and polymers.

• Battery cells: Lithium-ion chemistries such as NMC/NCA (nickel, manganese, cobalt), LFP (lithium iron phosphate), and emerging manganese-rich variants; graphite or silicon-graphite anodes; electrolytes with lithium salts and organic solvents; ceramic/polyolefin separators.
• Battery packs: Aluminum housings, cooling plates and thermal interface materials, foams and fire-resistant barriers, copper/aluminum busbars, and advanced battery management PCBs.
• Electric motors: Copper windings and electrical steel laminations; many use rare-earth permanent magnets (NdFeB with possible dysprosium/terbium), while others use induction or switched-reluctance designs to avoid rare earths.
• Power electronics: Silicon and increasingly silicon carbide (SiC) MOSFETs for inverters and DC‑DC converters; gallium nitride (GaN) appears in some onboard chargers; high-thermal-conductivity substrates and heat sinks.
• Thermal management: Aluminum radiators, brazed heat exchangers, pumps, and glycol-based coolants for batteries, motors, and electronics.

This hardware emphasizes conductivity, thermal stability, and safety, with a shift toward materials that improve efficiency, range, and recyclability.

Interior, safety, and comfort

Cabin materials prioritize comfort, durability, and crash protection, while meeting strict fire, chemical, and off‑gassing standards.

• Seating and soft trims: Polyurethane foams; textiles (polyester, nylon), microfiber, leather or synthetic leather (PU/PVC-coated fabrics).
• Interior plastics: PP, ABS, PC‑ABS, ASA, and PVC for dashboards, door panels, consoles; wood or metal veneers in premium models.
• Safety systems: Airbags (nylon fabrics), seatbelts (high-tenacity polyester), steering columns and reinforcements in high-strength steels.
• Glazing and visibility: Laminated windshield glass (PVB interlayer), tempered side/rear glass; head-up display-compatible laminates.
• NVH and insulation: Foam and fiber mats, bitumen sheets, recycled PET felts, and acoustic glass for noise and thermal control.
• Carpets and headliners: PET/nylon fibers, natural fibers in some models (hemp, kenaf) bound with polymer resins.

These materials achieve a balance between tactile quality, weight, and safety while enabling design flexibility and increasingly higher recycled content.

Wheels, tires, and suspension

The ride, handling, and durability of a car depend on robust materials under cyclical loads and varying temperatures.

• Tires: Blends of natural and synthetic rubber, carbon black and silica fillers, steel belts, and textile cords (polyester, nylon, aramid); inner liners use halobutyl rubber for air retention.
• Wheels: Stamped steel rims or cast/forged aluminum alloys; some performance models use magnesium or carbon fiber wheels.
• Suspension and brakes: Forged/cast steels and aluminums for control arms, knuckles, subframes; springs (steel), bushings (elastomers); brake discs (cast iron, carbon-ceramic in high-end cars), pads (composites with copper-reduced formulations).

Component choices aim to withstand fatigue and heat while keeping unsprung mass low for better dynamics and efficiency.

Electrical and electronics

As software-defined features expand, the electronic content of vehicles has surged, bringing complex wiring, computing, and sensing materials.

• Wiring and connectors: Primarily copper conductors (some aluminum in weight-sensitive harnesses), tin/silver solders, and various thermoplastics for insulation and connector housings.
• Printed circuit boards: FR‑4 (glass-fiber/epoxy) laminates, copper traces, and conformal coatings; ceramic substrates for high-power modules.
• Semiconductors and sensors: Silicon microcontrollers and memory; SiC/IGBT power devices; radar, lidar, camera sensors; MEMS for airbags and stability control.
• Displays and HMI: Glass with indium tin oxide (ITO) coatings for touch, OLED or LCD panels, polycarbonate lenses for switches and backlit controls.
• 12‑volt systems: Lead‑acid batteries remain common; lithium‑ion 12V packs are increasingly used in EVs for weight and durability.

These elements enable advanced driver assistance, connectivity, and electrification, with high-reliability materials designed for automotive temperature and vibration ranges.

Fluids and consumables

Operational fluids ensure lubrication, cooling, braking, and climate control, each formulated for specific thermal and chemical requirements.

• Engine and gear oils: Synthetic and semi-synthetic lubricants with additive packages for wear protection and efficiency.
• Coolants: Ethylene glycol or propylene glycol-based antifreeze with corrosion inhibitors; specialized coolants for EV battery and power electronics loops.
• Brake fluid: Glycol ether-based DOT 3/4/5.1 or silicone-based DOT 5 (non-ABS common); copper limits increasingly regulated.
• Refrigerants: R‑1234yf is the current standard in most new vehicles for lower global warming potential; some EV heat pumps use CO₂ (R‑744).
• Other: Windshield washer fluid, differential and transfer case fluids, greases, and diesel exhaust fluid (urea) for SCR systems.

Proper fluid selection and maintenance protect components, maintain efficiency, and meet environmental standards.

Typical material breakdown by weight (ICE vehicles)

While every model differs, most 2020s internal-combustion passenger cars fall within these approximate mass shares.

• Steel and iron: about 55–65%
• Aluminum: about 5–12%
• Plastics and composites: about 8–15%
• Rubber and elastomers: about 5–8%
• Glass: about 2–4%
• Copper and other nonferrous metals: about 1–2%
• Fluids and miscellaneous: about 3–6%

Premium, performance, and off-road vehicles may shift toward more aluminum, composites, and higher-capacity cooling and braking systems.

Typical material breakdown by weight (EVs)

EVs redistribute mass toward batteries, motors, and power electronics, often increasing aluminum and copper content.

• Battery pack (cells + pack hardware): about 20–30% of vehicle mass
• Steel and iron: about 35–50% (depending on platform and crash requirements)
• Aluminum: about 10–25% (including pack enclosures and large castings)
• Plastics and composites: about 8–15%
• Copper: about 2–4% (high-voltage cabling, motors)
• Glass, rubber, and others: about 5–10%

Design choices such as structural battery packs, rare-earth-free motors, and multi-material bodies can move these percentages significantly.

Sustainability, sourcing, and trends

Regulatory pressure and consumer demand are accelerating shifts toward lighter, lower-carbon, and more recyclable materials across the industry.

• Lightweighting: Increased use of AHSS, aluminum, magnesium, and composites; topology optimization and large aluminum castings reduce part count and mass.
• Recycled content: Wider adoption of recycled aluminum, steel, and plastics (e.g., recycled PP/PET) without compromising performance.
• Bio-based and natural fibers: Door and dash substrates with kenaf, hemp, or flax; bio-based polymers and foams in select components.
• Low-CO₂ metals: Green steel via hydrogen direct-reduced iron (H2‑DRI) and EAF routes; renewable-powered aluminum smelting.
• Battery evolution: Growth of LFP (cobalt-free), manganese-rich chemistries, and silicon-enhanced anodes; scaling of battery recycling for lithium, nickel, cobalt, and copper recovery.
• Magnet strategies: Reduced or no rare-earth motor designs; magnet recycling and demagnetization technologies to reclaim NdFeB materials.
• Chemicals and HVAC: Transition to low-GWP refrigerants (R‑1234yf, R‑744) and copper-reduced brake pads to meet environmental regulations.

These changes aim to cut lifecycle emissions and improve resource security while keeping safety and performance at the forefront.

Why these materials are chosen

Automakers select materials through a multi-criteria lens to meet engineering, regulatory, and cost targets worldwide.

• Strength-to-weight and stiffness: Enables crash safety and handling without excessive mass.
• Durability and corrosion resistance: Ensures longevity under thermal, chemical, and mechanical stress.
• Manufacturability and cost: Supports stamping, casting, molding, bonding, and scalable production.
• Safety and NVH: Manages crash energy, fire performance, noise, and vibration.
• Thermal and electrical performance: Critical for engines, batteries, motors, and electronics.
• Recyclability and sustainability: Increasingly mandated and valued in markets worldwide.

The final material mix is a compromise that reflects the vehicle’s mission—efficiency, performance, utility, or cost leadership.

Summary

Cars blend steels, aluminum, magnesium, composites, plastics, rubber, glass, and sophisticated electronic materials; EVs add battery and motor-specific metals and ceramics. The exact recipe varies by vehicle type and purpose, with industry momentum favoring lighter, more recyclable, and lower‑carbon materials while maintaining safety, performance, and affordability.

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. 

What equipment is used to make cars?

Manufacturing equipment refers to the machinery, tools, and devices used in the production process. In the automotive industry, this includes a wide array of equipment ranging from assembly robots and CNC machines to injection molding machines and automated inspection systems.

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.