The Top 5 Materials Driving Auto Manufacturing

Ever stopped to think about what makes up your car? Not in terms of speed or its performance on a race track, but the actual materials used in its construction?

We often hear about car components like engines, transmissions, seats, and HVAC systems, but we rarely consider the raw materials that go into creating these vital parts.

The auto industry relies on a vast array of materials, including iron, aluminum, plastic, steel, glass, rubber, petroleum products, and copper. These materials are used to craft everything, from the smallest parts like dashboard needles and wiring, to the larger components like engine blocks and transmission gears.

Over the decades, these materials have advanced significantly, becoming more refined, durable, and safer. Their evolution has paralleled the growth of automotive manufacturing technologies, leading to increasingly innovative applications.

In this article, we’ll explore five of the most commonly used materials in car manufacturing. First, let’s focus on the one that contributes most to a car’s overall weight.

5: Steel

In modern vehicles, steel is the primary contributor to their weight. For instance, in 2007, the average car contained approximately 2,400 pounds (1,090 kilograms) of steel, while most pickup trucks and SUVs used around 3,000 pounds (1,360 kilograms) [source: Sherefkin]. With most cars now weighing about 3,000 pounds and SUVs around 4,000 pounds (1,810 kilograms), that’s an immense amount of steel!

In modern cars, steel is essential for forming the chassis or frame beneath the body, providing the vehicle's skeletal structure and protecting occupants in the event of a crash. Steel is used in door beams, roofs, and even body panels in most cars today. Additionally, steel is used in various parts of the vehicle, such as the engine compartment and exhaust systems, with stainless steel often used for exhaust components.

Steel manufacturing has advanced significantly, allowing automakers to produce different types of steel suited for specific parts of the vehicle, some of which are rigid while others are designed to crumple on impact. These innovations in automotive manufacturing contribute to your safety on the road [source: Fountain].

4: Plastic

Next time you're inside your car, channel Dustin Hoffman’s character from "The Graduate" and think of one word: Plastics. Today's cars use vast amounts of plastic in their construction, with plastics making up about 50 percent of new cars today [source: American Chemistry Council]. It's no surprise, as plastics are durable, inexpensive to produce, and can be molded into almost any shape.

Your dashboard, gauges, dials, switches, air vents, door handles, floor mats, seat belts, airbags, and many other components are made from various types of plastics.

Along with dashboard components, many small parts inside the engine, like the oil dipstick handle, are also crafted from plastic. Due to their lightweight properties, plastics are increasingly used in body structures and engine components during automotive production.

3: Aluminum

In automotive manufacturing, aluminum is considered a relative newcomer, being increasingly favored for its lightweight yet durable qualities. In 2009, aluminum accounted for about 9 percent of the weight in most modern vehicles, compared to 5 percent in 1990 and just 2 percent in 1970 [source: Aluminum Association].

Aluminum is used in automotive manufacturing to produce lighter body panels, contributing to vehicles that prioritize performance. Beginning with the early 1990s Acura NSX, many supercars, including the iconic Audi R8, have been built using aluminum. Additionally, aluminum is commonly used for wheels in many cars.

Furthermore, more car manufacturers are transitioning from traditional iron engine blocks to aluminum. While aluminum may not offer the same level of durability as iron, its lighter weight significantly enhances overall performance.

2: Rubber

What’s the one thing every car has in common? They all require tires to move. Tires are often overlooked, but they are one of the most crucial parts of any vehicle. This is where the significance of rubber in automotive manufacturing comes into play.

The rubber industry is primarily driven by automotive manufacturing, with around 75 percent of the world’s natural rubber production being used to make vehicle tires [source: Industrial Rubber Goods]. The rubber tire helps protect the rest of the wheel and its internal components from wear, which can improve fuel efficiency and enhance road safety.

Beyond tires, rubber is used in parts such as wiper blades, engine mounts, seals, hoses, and belts. Like plastic, rubber is a durable, cost-effective, and versatile material with a broad range of applications in the automotive industry.

1: Glass

What use is a car if you can’t see through it? Like rubber, glass plays an essential but often overlooked role in automotive manufacturing. It’s closely tied to the auto industry, and when car sales slump, glass manufacturers also face job losses [source: Glass Magazine].

Glass plays a crucial role in several components of your car. Most notably, it is used to create windshields, providing you with clear visibility while offering protection from flying debris. Additionally, glass is utilized for rearview and side mirrors, enhancing your awareness of the surroundings while driving. Furthermore, fiberglass, a close relative of glass, serves as a popular insulation material in automotive manufacturing.

With technological advancements, glass is being incorporated into even more innovative car parts. For instance, it’s now used in the creation of navigation displays and lenses for back-up cameras, giving drivers a clearer view of the area behind them for added safety and convenience.