Lightweight and High Strength Materials for ICE Vehicles

Detailed overview of innovation with sample startups and prominent university research

What it is

Lightweight and high-strength materials are materials that possess a high strength-to-weight ratio, allowing for the construction of vehicles that are both strong and lightweight. These materials include:

  • High-Strength Steel (HSS): Advanced steel alloys with enhanced strength and formability, allowing for thinner and lighter components while maintaining structural integrity.
  • Aluminum: A lightweight and corrosion-resistant metal commonly used in body panels, engine components, and wheels, significantly reducing weight compared to traditional steel.
  • Magnesium: Even lighter than aluminum, magnesium alloys offer excellent strength-to-weight ratios but can be more challenging to work with.
  • Carbon Fiber Composites: These materials consist of carbon fibers embedded in a resin matrix, offering exceptional strength and stiffness at a very low weight.

Impact on climate action

Utilizing lightweight, high-strength materials in Low-Carbon ICE Vehicles significantly reduces emissions by enhancing fuel efficiency and performance. This innovation minimizes the carbon footprint of conventional vehicles, fostering a transition towards greener transportation options and accelerating climate action by curbing greenhouse gas emissions from the automotive sector.


  • Material Science: Advancements in material science have led to the development of alloys and composites with improved properties, including higher strength, better formability, and increased corrosion resistance.
  • Manufacturing Processes: Innovative manufacturing processes, such as hot stamping for HSS and advanced composite manufacturing techniques, enable the efficient and cost-effective production of lightweight components.
  • Computer-Aided Design (CAD) and Simulation: CAD software and simulations help engineers optimize the design of vehicle structures using lightweight materials, ensuring strength, safety, and crashworthiness.
  • Life Cycle Analysis: Evaluating the environmental impact of lightweight materials throughout their lifecycle, from production to recycling, is crucial to ensure their overall sustainability.

TRL : 8-9

Prominent Innovation themes

  • Third-Generation Advanced High-Strength Steels (AHSS): These steels offer even greater strength and formability, allowing for thinner and lighter components without compromising safety.
  • Magnesium Sheet Metal Forming: Developing new forming processes that enable the efficient and cost-effective use of magnesium sheet metal in vehicle body panels, further reducing weight.
  • Carbon Fiber Reinforced Plastics (CFRP) in Mass Production: Innovating in CFRP manufacturing techniques to reduce costs and enable the wider adoption of this lightweight and high-strength material in mass-produced vehicles.
  • Bio-Based Composites: Exploring the use of sustainable, bio-based materials, such as natural fibers like hemp or flax, to reinforce composites, reducing reliance on petroleum-based materials and lowering environmental impact.
  • Multi-Material Structures: Optimizing the use of multiple materials in a single vehicle structure, leveraging the strengths of each material to minimize weight while maintaining strength and safety.

Other Innovation Subthemes

  • Advanced High-Strength Steel Alloys
  • Aluminum Lightweight Solutions
  • Magnesium Alloy Innovations
  • Carbon Fiber Composite Advancements
  • Innovative Material Science
  • Hot Stamping Technology
  • Advanced Composite Manufacturing
  • Computer-Aided Design Optimization
  • Third-Generation AHSS Development
  • Magnesium Sheet Metal Forming Techniques
  • CFRP Mass Production Methods
  • Multi-Material Structure Optimization
  • Lightweight Material Recycling Technologies
  • Crashworthiness in Lightweight Vehicles
  • Cost-Effective Lightweight Solutions

Sample Global Startups and Companies

  • Alcoa:
    • Technology Focus: Alcoa is a global leader in lightweight metals technology, engineering innovative solutions primarily based on aluminum and other lightweight alloys. Their advancements often involve alloy development, manufacturing processes, and surface treatments to enhance strength while reducing weight.
    • Uniqueness: Alcoa’s uniqueness lies in its long-standing expertise in metallurgy and its ability to produce lightweight materials suitable for various applications, including aerospace, automotive, and consumer electronics.
    • End-User Segments: Their materials find applications across industries such as aerospace, automotive, packaging, and construction, where lightweighting is crucial for improving fuel efficiency, performance, and sustainability.
  • Novelis:
    • Technology Focus: Novelis specializes in aluminum rolling and recycling, producing high-strength, lightweight aluminum sheets for various industries. Their focus is on continuous innovation in alloy development, rolling processes, and recycling technologies to meet the demand for sustainable lightweight materials.
    • Uniqueness: Novelis stands out for its integrated approach to aluminum production, from recycling scrap aluminum to producing advanced rolled products with enhanced strength and formability. Their closed-loop recycling system contributes to their sustainability goals.
    • End-User Segments: Their materials cater to industries such as automotive, beverage packaging, consumer electronics, and building and construction, where lightweight, durable, and recyclable materials are sought after.
  • Toray Industries:
    • Technology Focus: Toray Industries is a diversified multinational corporation known for its expertise in advanced materials, including carbon fiber composites and other high-performance materials. Their focus is on developing lightweight yet strong materials for applications ranging from aerospace to sporting goods.
    • Uniqueness: Toray Industries is known for its cutting-edge carbon fiber technology, offering materials with exceptional strength-to-weight ratios and superior mechanical properties. Their continuous research and development efforts drive innovation in lightweight materials.
    • End-User Segments: Their materials find applications in aerospace, automotive, sporting goods, industrial equipment, and various other sectors that demand lightweight, high-strength materials for performance-critical applications.

Sample Research At Top-Tier Universities

  • University of Michigan:
    • Technology Enhancements: Researchers at the University of Michigan are focusing on developing lightweight materials with high strength-to-weight ratios for application in low-carbon ICE vehicles. They are exploring advanced manufacturing techniques such as additive manufacturing and composite materials to produce components that are both lightweight and durable.
    • Uniqueness of Research: The research at the University of Michigan involves a holistic approach that considers the entire lifecycle of materials, from sourcing to end-of-life recycling. They are investigating sustainable alternatives to traditional materials, such as carbon fiber reinforced polymers (CFRP) and aluminum alloys, to reduce the environmental footprint of vehicle manufacturing.
    • End-use Applications: The lightweight and high-strength materials developed at the University of Michigan have applications in various components of low-carbon ICE vehicles, including chassis, body panels, and engine components. By reducing vehicle weight, these materials contribute to improved fuel efficiency and lower emissions, helping to mitigate the environmental impact of conventional vehicles.
  • Aachen University:
    • Technology Enhancements: Aachen University’s research focuses on optimizing the microstructure and mechanical properties of lightweight materials for low-carbon ICE vehicles. They are employing advanced characterization techniques such as electron microscopy and X-ray diffraction to understand the relationship between material structure, processing, and performance.
    • Uniqueness of Research: The research at Aachen University is distinguished by its emphasis on fundamental materials science principles combined with practical engineering applications. They are developing novel alloy compositions and heat treatment processes to enhance the strength, fatigue resistance, and corrosion resistance of lightweight materials.
    • End-use Applications: The lightweight and high-strength materials developed at Aachen University are suitable for various components of low-carbon ICE vehicles, including engine blocks, transmission housings, and suspension components. By replacing traditional materials with lightweight alternatives, vehicle manufacturers can achieve significant weight savings without compromising performance or safety.
  • Imperial College London:
    • Technology Enhancements: Researchers at Imperial College London are exploring innovative materials and manufacturing techniques to produce lightweight components for low-carbon ICE vehicles. They are investigating the use of advanced materials such as carbon nanotubes, graphene, and metal matrix composites to achieve high strength and stiffness while minimizing weight.
    • Uniqueness of Research: The research at Imperial College London is characterized by its interdisciplinary approach, combining expertise in materials science, mechanical engineering, and automotive technology. They are collaborating with industry partners to translate fundamental research findings into practical solutions for lightweight vehicle design.
    • End-use Applications: The lightweight and high-strength materials developed at Imperial College London have applications in critical components of low-carbon ICE vehicles, including engine blocks, drivetrain components, and structural reinforcements. By incorporating these advanced materials into vehicle design, manufacturers can improve fuel efficiency, reduce emissions, and enhance overall vehicle performance.

commercial_img Commercial Implementation

Lightweight and high-strength materials are widely implemented in commercial vehicles across all segments. Automotive manufacturers are increasingly using high-strength steel, aluminum, and carbon fiber composites to reduce vehicle weight and improve fuel efficiency.