Cars and other automobiles consist of a wide range of materials. Some are chosen for their strength, while others are better for being lightweight and affordable. Yet, electric cars have different priorities, forcing manufacturers to rethink what materials they use to make them.
EV cars have to accommodate an exceptional amount of weight from the battery packs that they carry. Because of that, manufacturers have to prioritize using strong but lightweight materials. Aluminum and steel satisfy those needs when building the car’s structure. Still, rare earth metals and composite materials also play a crucial role.
In this guide, we’ll take a deep dive into the handful of different materials that manufacturers use in making their electric cars.
Why Is A Car Made Of Different Materials?
Firstly, it’s crucial to understand that manufacturers do not use only one material to make electric cars and other vehicles. Instead, they rely on a combination of metals and other materials for various parts of the vehicle.
When EV car manufacturers choose the materials for their vehicles, they must consider two things above all else:
- Safety for the vehicle and its occupants.
- Performance, like speed and range.
Each kind of material comes with its strengths and weaknesses. So, EV car manufacturers compete by choosing a unique combination of materials to get the best out of their models.
How Does Weight Affect Electric Cars?
At first thought, it’s easy to assume that EV cars are lightweight because they don’t carry a combustion engine. But, sadly, that couldn’t be further from the truth.
Electric cars and other vehicles rely on battery packs to store and deliver power to their motors. Unfortunately, those battery packs are incredibly heavy. Having too much weight on the car will significantly stress the electric motors and reduce the vehicle’s range.
As a result, EV car manufacturers focus on using lightweight and durable materials in the models they make. That way, each EV car can still perform well in terms of its speed and range without sacrificing safety or quality.
What Materials Are Used To Make Electric Cars?
As seen above, manufacturers use different materials to make electric cars. Those materials include aluminum, steel, copper, rare earth metals, and composite materials.
Each one has unique purposes, strengths, and weaknesses that make the electric car perform well. So, let’s take a closer look at each one and how they contribute to the EV car’s construction.
#1 Aluminum
One of the most crucial materials manufacturers use in building EV cars is aluminum. You’ll find that they use this material primarily for the body and chassis of the vehicle.
The main benefit of aluminum is that it has a low density. That means it provides a solid structure for the vehicle’s frame while also remaining incredibly lightweight.
As we saw in the previous section, lightweight materials are critical for electric cars and other vehicles. A lighter car is also more energy-efficient and can travel further on a single charge.
#2 Steel
Next on the list is steel, which is also popular because of its relatively light weight. However, this material has several advantages, including being cheaper, more robust, stiffer, and can also absorb energy.
As you might guess, those are precisely the kind of qualities you want when it comes to increasing a vehicle’s safety. By being able to absorb energy while staying stiff, steel helps to reduce damage and prevent injury during a collision on the road.
That’s why EV manufacturers tend to use steel on car sections that are most likely to suffer impact during a crash.
#3 Copper
There’s lots of talk about EV car batteries and their materials these days. But as we’ve mentioned in the title, we’re not talking about that here.
Instead, we’re looking at other EV parts that don’t get as much attention, like their chargers and motors. These components are responsible for generating power and torque, forming the basis of the car’s performance.
Here, one material that manufacturers must rely on is copper. This material is so vital that EVs these days use up to 4 times more copper than you’d find inside a conventional, internal combustion engine vehicle.
Copper plays such a crucial role in EV cars because it’s durable, reliable, and most importantly because it’s an excellent electrical conductor.
In simple terms, copper helps carry electricity without much resistance and therefore does not generate lots of heat as other materials would.
#4 Rare Earth Metals
Some EV car manufacturers are moving away from using copper in their motors, however. Instead, they rely on rare earth metals like neodymium, resulting in more efficient electric motors.
Despite the benefits, not all EV manufacturers use rare earth metals. Those metals are harder to get and only come from a few countries worldwide. Yet, the material is in high demand not only for EVs but also other electronic devices.
Copper, however, offers a much more stable supply that EV makers can rely on without any interruptions. So, many EV manufacturers stick with this material to avoid any supply headaches that could jeopardize their output of new EV cars.
#5 Composite Materials
The EV space is incredibly competitive, especially since world-leading automotive companies have already started competing in it. So, there’s a lot of pressure for companies to find and use affordable, strong, and lightweight materials.
One category of materials that top EV carmakers are exploring is composite materials. These are unique materials that offer plenty of strength without adding excessive weight to the electric car.
Some composite materials already in use include polypropylene embedded with fiberglass and other carbon fiber materials. You’ll find that the companies using these materials are market leaders like BMW and VW because they have the resources to do so.
Unfortunately, composite materials are still far too expensive for many other EV carmakers to make use of in their vehicles.
The future for EV Materials
The EV car industry is incredibly competitive and continues to grow rapidly. That’s excellent news because it forces EV carmakers to invest in finding and creating much better materials for their cars.
As time goes on, car buyers will be the ones who win as they get to enjoy electric cars and other vehicles that are more affordable and perform exceptionally well.