Millions of people each year get a motor insurance quote, most will drive the vehicle everyday and have no idea about its weight, or that it has been getting heavier in recent years. Most of the weight on cars today comes from steel. Only a few years ago the average car contained 2,400 pounds of steel. Now, consider that most cars weigh around 3,000 pounds, that’s a lot of steel. In cars, it is steel that is used to create the underlying chassis underneath the body. This forms the skeleton of the car and will protect the driver and passengers in the event of a crash. Doors, roofs and even the body panels made during manufacturing on most cars today are made of steel. Steel is also used in a number of different areas throughout the vehicle. Even the exhaust will often be made from stainless steel.
The manufacturing of steel has evolved massively, enabling carmakers today to be able to use different types of steel for parts of the vehicle. However, it still remains a fact that in order for us to get better mileage and lower emissions in the future, vehicles will have to lose some weight. That will not be easy with drivers demanding more creature comforts inside the vehicle. It would be a bad business move on the manufacturer’s part to stop offering the latest technology that make for a comfortable drive. Yet it is the technology that makes cars heavier.
One answer would be to make body parts out of lighter materials like carbon fibre-reinforced plastic, which is often abbreviated as CFRP. Like many other auto innovations, this one started out life in the racing world for a long time before seeing it in the consumer marketplace. CFRP works pretty much like fibre glass which sees the carbon fibre spun into long strands and then arranged into a weave for strength. A plastic material (the polymer) is soaked into the carbon fibre around a mould. When the two harden, the result will be both strong and quite light (50% lighter than forming the part out of metal alloy). This is very expensive, and because of this it is still uncommon on vehicles that are mass produced.
Chevrolet already makes limited use of carbon fibre on some of its factory models. Lexus is using CFRP extensively on its LF-A to be released next year, and they say more carbon fibre cars will be released in the future. BMW have used carbon fibre for the roof of its M3 sports car, and they have plans to use it on a wider scale for its eco-friendly city car which is expected around 2015.