Composites Use in Automotive
Composites are used frequently in motorsports and lower volume, high-end/luxury vehicles, which typically favor continuous carbon fiber materials. They are also often used to fabricate exterior structures in racing vehicles, where their relative light weight provides speed and performance advantages over metals. Within mid- and high-volume production vehicles, common composite applications include glass fiber-reinforced polymer (GFRP) leaf springs, suspension components, and drive shafts, sheet molding compound (SMC) body panels and frames; bulk molding compound (BMC) housings and support structures; and injection-molded thermoplastics for bumper frames, lift gates and seat structures.
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BMW X5 enters final test phase, prepares for 2026-2028 series rollout
The BMW X5 is completing final calibration drives prior to production, with iX5 EV and iX5 Hydrogen versions to follow featuring a high-voltage battery and CFRP tanks in the iX5.
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PulPro-SMC project achieves weld-free composite rail vehicle joints in single pressing step
SNAPSHOT: Three-year R&D collaboration led by HÖRMANN Vehicle Engineering has demonstrated a pultrusion-SMC bonding method that eliminates separate joining hardware and reduces weight by 20% versus conventional steel construction.
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Alef Aeronautics' composites-intensive flying car enters production phase
The Model A Ultralight — a drive-and-fly eVTOL designed to lift off directly from public roads — marks the first step toward full-scale Model A manufacturing.
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Industry shows successful integration of flax-linen, hemp fiber into advanced composites processes
Natural fiber composites are quickly emerging as serious contenders across demanding sectors, with proven use in filament winding, 3D printing, AFP and other automated processing techniques.
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Autoneum BEV battery lid prototype unites multifunctionality and composites
Integration of multiple protective functions in a single lightweight part simplifies battery pack designs and elevates safety and efficiency for EV platforms.
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NeMo.bil project commissions complete H2 powertrain in prototype vehicle
Partners Avanco Composites, Poppe + Potthoff GmbH and Aspens GmbH joined in commissioning a full H2 powertrain, validating the TCU’s sensor acquisition, safety intervention and CAN-based communication with the vehicle control unit.
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Latest Automotive News And Updates
Sustainable Envalior Tepex variant delivers identical performance, 50% reduced carbon footprint
Envalior’s LCA and external critical review verifies the new Tepex composite matches the original’s performance for automotive and can be used as a drop-in for composites processes.
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SPE ACCE 2026 second keynote tackles materials potential in automotive
Dr. Paul E. Krajeweski, a director at the General Motors Global Research and Development Center, will share insights on key opportunities and how to collectively drive progress.
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Bpreg Composites natural fibers prove industrial readiness on reECONIC EV concept vehicle
SNAPSHOT: Automotive project, demonstrating recycled, natural and bio-based materials, includes interior UD thermoplastic prepregs with mass-scale production protential.
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Far-UK successfully develops, supplies rGF cab support brackets for Mercedes testing
SNAPSHOT: Lessons learned from the RECOTRANS project bolster support brackets designed with lightweighting, cost, durability and EOL considerations.
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Topolo-Truck innovates fiberglass honeycomb panels for caravan body shells
SNAPSHOT: GFRTP panels align with environmental trends and enhance core requirements like lightweighting, structural strength and waterproofing.
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Mansory debuts widebody Emperor Signature with full carbon fiber bodywork
Complete widebody conversion for the Rolls-Royce Cullinan Black Badge features forged carbon fiber bodywork, 24-inch wheels and up to 720 horsepower.
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Featured Posts
Report: Composites and Carbon Fiber Use in Hydrogen Storage
A first-of-its-kind technical report that assesses the materials, manufacturing processes, market and energy trends driving use of carbon fiber composites in global hydrogen (H₂) storage applications for fuel cell-powered trucks, buses, trains and passenger vehicles.
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Advancing the thermoplastic composite battery enclosure into production
Having achieved its first few commercial series successes, Kautex Textron explains the design process for its Pentatonic battery enclosure platform, which comprise glass fiber/PP or PA6 and injection overmolding a compression molded laminate.
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Advancing bonding, coating and sealing to 4.0 systems for composites, metals and more
Brighton Science uses decades of experience, 2-second surface measurements and a framework of data-based specs and KPIs to help manufacturers advance toward reliable, predictable bond quality for faster, high-performance production.
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Sentherm conductive polymers match aluminum thermal performance, cut weight
Tailored filler networks, anisotropic material design and manufacturing process control achieve hybrid polymers for EVs, batteries and other automotive-related electronics with 95% of aluminum’s thermal performance and 25-45% reduced component weight.
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Polestar 5 takes aesthetics and circularity approach to biocomposite seatback design
The 2026 Polestar 5 expands the company’s use of sustainable materials design in the interior, including flax fiber/thermoplastic seatbacks that save 7 kilograms of weight and reduce overall plastics use.
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Biocomposites demonstrated as drop-in material option for truck interiors
Ongoing trials from Volvo Trucks with Forvia Group and subsidiary Materi’Act aim to prove out and commercialize biocomposites made from waste oyster shells for future long-haul truck platforms.
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FAQ: Automotive
How are composites used in automotive structures?
Within mid- and high-volume production vehicles, common composite applications include glass fiber-reinforced polymer (GFRP) leaf springs, suspension components, and drive shafts, sheet molding compound (SMC) body panels and frames; bulk molding compound (BMC) housings and support structures; and injection-molded thermoplastics for bumper frames, lift gates and seat structures.
As electric vehicles (EV) become more prevalent on the road and in development by automotive manufacturers, new opportunities exist for composites and composite materials development. For example, a lighter-weight, composites-intensive vehicle is likely capable of driving for a longer range between charges. Battery enclosures present one large market opportunity in the EV market.
Why use composites for electric vehicle (EV) battery enclosures?
As the automotive industry rapidly electrifies its fleets, interest is growing among OEMs and battery module producers in using composite materials for battery enclosures — covers and trays that hold and protect the frames and battery cells themselves.
There are many reasons for this, including the ability to reduce mass and stack tolerances, the fact that battery enclosures are multicomponent assemblies and poor impact performance of metals. In each of these areas, composite battery enclosures offer quantifiable benefits versus metals: lower mass, higher design freedom with greater space efficiency, faster assembly, no corrosion, greater durability and — with specific formulations — better flame resistance/fire containment.
Source: Price, performance, protection: EV battery enclosures, Part 1
