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Automotive Lightweighting Market, Global, 2024–2030

Publisher Frost & Sullivan
Published Sep 29, 2025
SKU # MC20451243

Description

This Frost & Sullivan report examines automotive lightweighting strategies, highlighting the various initiatives adopted by original equipment manufacturers (OEMs) to reduce the weight of passenger vehicles. As the industry rapidly advances toward electrification and sustainability, reducing vehicle weight has become a crucial lever for meeting emissions targets, enhancing energy efficiency, and lowering costs. Lightweighting enables automakers to improve fuel economy, extend electric vehicle (EV) driving range, and optimize powertrain design, all while maintaining structural strength and safety. The adoption of advanced materials combined with innovative manufacturing techniques allows manufacturers to achieve these gains without compromising durability. Although carbon dioxide and fuel economy regulations strongly incentivize weight reduction, the absence of explicit mandates leads to uneven implementation across the sector. Nonetheless, as electrification, advanced driver assistant systems (ADAS), and connected vehicle features add to vehicle weight, lightweighting will become even more critical to deliver performance, range, and cost efficiency. Over the next decade, multi-material architectures, structural battery integration, and holistic vehicle design approaches are expected to make lightweighting a core enabler of next-generation mobility solutions. The report identifies the factors driving and restraining the industry as well as the growth opportunities arising from emerging lightweighting trends for market players and stakeholders to leverage. The geographical scope of this study is global. The base year is 2024, and the forecast period is from 2025 to 2030.

Table of Contents

    • Why is it Increasingly Difficult to Grow?
    • The Strategic Imperative 8TM
    • The Impact of the Top 3 Strategic Imperatives on the Automotive Lightweighting Industry
    • Scope of Analysis
    • Competitive Environment
    • Key Competitors
    • Growth Drivers
    • Growth Restraints
    • Key Takeaways
    • Lightweighting for Improved Fuel Efficiency
    • Lightweighting for Enhancing Performance
    • Lightweighting for Reducing CO2 Emissions
    • Lightweighting for Improving Sustainability
    • Vehicle Component Lightweighting Potential
    • Analysis of Lightweighting Materials in Vehicles (2024 vs 2030)
    • Select OEM Lightweighting Activities
    • Key Regional Government Regulations/Standards/Announcements Impacting Lightweighting
    • Why Lightweighting is Important
    • Types of Lightweighting Methods in the Automotive Industry
    • Key Lightweighting Methods Analysis
    • Recent Trends in Lightweighting
    • Lightweighting in Different Vehicle Segments
    • Select OEM Initiatives and Lightweighting Benefits Observed
    • Key Lightweight Materials in Cars
    • Key Lightweight Materials: Comparative Analysis
    • 2024 vs. 2030 Material Composition in Vehicles
    • Lightweighting Properties Comparison
    • HSS-Industry Strategy
    • Aluminium-Industry Strategy
    • Magnesium-Industry Strategy
    • Plastics-Industry Strategy
    • Natural Fiber Composites-Industry Strategy
    • CFRP-Industry Strategy
    • Future Material Trends in Lightweighting
    • Key Lightweighting Strategies in Vehicle Design
    • Topology Optimization
    • Steps in Topology Optimization
    • AI-driven Generative Design for Lightweighting
    • Examples of OEMs using AI-generative Design for Lightweighting
    • Modular Platforms for Lightweighting
    • Key Lightweighting Strategies in Vehicle Manufacturing
    • Gigacasting in Automotive Manufacturing
    • Tesla Approach to Gigacasting
    • Vehicle Body Gigacasting: Select OEM Initiatives by Regions
    • Industry Focus on Hypercasting for Next-gen EVs
    • Hot Stamping
    • Comparative Analysis of Gigacasting vs. Hot Stamping Process
    • Gestamp Profile: Hot Stamping
    • Additive Manufacturing/3D Printing for Lightweighting
    • Multi-material Bonding using 3D Printing: Case Study
    • Key Lightweighting Strategies in EV Batteries
    • Lightweighting EV Batteries: Overview
    • Comparative Analysis of EV Battery Lightweighting Strategies
    • EV Battery Structural Integration
    • Alternate Lightweight Battery Compositions
    • Lightweight Materials for Battery Design
    • Case Study: Lightweight Materials for Battery Enclosures
    • Cell-to-pack Technology
    • Future Design Trends in Battery Lightweighting
    • Growth Opportunity 1: Innovations in Advanced Lightweight Materials
    • Growth Opportunity 2: Shift in Automotive Supply Chain
    • Growth Opportunity 3: Lightweighting EV Batteries
    • Benefits and Impacts of Growth Opportunities
    • Next Steps

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