5 Most Used Materials in Car Manufacturing

The idea of cars came in when horse-drawn carriages were used to move around. These carriages were made of wood, so at that time, it seemed logical that the car body and chassis be made of wood. However, metal fabrication replaced it soon and steel became the metal of choice to make the body and chassis. The famous Model T car by Ford had metal chassis in 1908 and a few years later the Dodge brothers built the first car that had an all-steel body.

While steel is still widely used in the car manufacturing industry due to its strength, durability, and affordability. There are other materials also that are now used in making cars. Let's explore them, starting with steel.

Steel: Steel is a versatile and essential material in car manufacturing, still used for a wide range of parts and components that contribute to the strength, durability, and safety of vehicles.

Steel manufacturing has improved a lot and it’s not surprising that the steel used in various components differs in quality and strength, depending on their purpose. Here’s a brief list of areas where it's used:

• Body Structure: Steel is used extensively in the car body structure for various applications. The car body structure typically includes the frame, body panels, and other supporting components, all of which are made of steel in most cases. 
• Body panels like roofs, hoods, doors, fenders, and trunk lids are made of steel. These panels are made using a process called stamping and steel is an ideal material for the process. This is so because steel is ductile and can be shaped into complex curves and contours.
• Steel is used for various safety features in cars, including door beams, roof-rail, B-pillars, roll cages, crash bars, and energy-absorbing structures. Steel provides the strength and durability required to protect occupants in the event of a crash.
• The chassis is the framework of the car body that supports the engine, transmission, and suspension system. It is usually made of steel and provides the necessary structural integrity to the vehicle.
• Suspension Components: Steel is used for various suspension components, including springs, control arms, and shock absorbers. Steel is ideal for these parts because it can withstand the high stresses and strains that are generated during driving.
• Engine Parts: Steel is used for various engine parts, such as crankshafts, cylinder blocks, and cylinder heads. Steel has the strength and durability required to withstand the high temperatures and pressures generated by the engine.
• Drive Train Components: Steel is used for various drive train components, including transmissions, axles, and differential gears. Steel provides the strength and durability required for these components, which are subjected to high levels of stress during driving.

Aluminum: Aluminum is becoming increasingly popular in auto manufacturing due to its lightweight and high strength-to-weight ratio.

Along with steel, aluminum is also used in parts such as engine blocks, wheels, suspension components, and body panels.

Aluminum is used in lightweight body panels for up to 50% weight savings compared to steel. This improves efficiency and helps in reducing emissions.
Alloy wheels are increasingly being used in cars. These are made of aluminum alloys to keep the wheels lightweight and rigid. They also provide better handling and at the same time are more attractive.
There are many more parts that are made of aluminum like valve covers, car badges, clutch parts, handles, alternator housings, transmission housings, and carburetor housings, to name a few.

Plastic: The use of plastic is not limited to just interior trim and bumpers, it's also used in various engine components like intake manifolds, air intake ducts, and engine covers.

As plastic has excellent electrical insulation properties it's ideal for making electrical components and is used in wiring harnesses, connectors, and insulation materials. It's also used in body moldings, grille surrounds, and mirror housings. Plastic is a cost-effective and versatile material that's used in a range of parts in a car.

Glass: Glass is used in the production of car windows, windshields, and mirrors. Different types of glass are used for different parts. A windshield is made of laminated glass.

In simple terms, it's a sandwich of two glass panes and a sheet of tough plastic resin (Poly-Vinyl-Butyral). This keeps the windshield together even if it breaks on impact.

The tempered glass used in car windows undergoes chemical and heat treatment. These treatments make it strong, and durable. It obviously provides excellent visibility, making it an important material for safety and visibility in cars.

Rubber: Rubber is used in the production of tires, hoses, belts, rubber seals, o-rings, manifold gaskets, spark plug boots, vibration dampers, engine mounts, flooring mats, and various other parts.

It is flexible, durable, and has excellent shock-absorbing properties, making it ideal for use in the automotive industry.

The auto industry is a leader in using a multitude of materials in manufacturing. There are much more materials used in car manufacturing than in any other industry.