Lightweight design
Lighter, stronger and more sustainable solutions with composites
Lightweight design has become a key driver in modern engineering and manufacturing. The need to improve sustainability, energy efficiency and lifecycle costs is accelerating the shift from traditional materials such as steel and aluminium to advanced composite solutions.
Across multiple industries, composites enable structures that are lighter, stronger and more durable — even in the most demanding operating environments.
Moving beyond steel and aluminium
Steel and aluminium have long been the foundation of industrial manufacturing thanks to their strength, durability and availability. However, their inherent properties increasingly limit modern design requirements.
Steel’s high-density results in heavy structures, often forcing compromises between weight and performance. Aluminium, while lighter, comes with trade-offs in stiffness, material cost and behaviour in low temperatures. It is also susceptible to galvanic corrosion when combined with other metals, adding complexity to design and maintenance.
Composites offer a fundamentally different approach.
Optimising strength, weight and durability
Composite materials deliver high structural performance without unnecessary mass, making them ideal for applications where weight reduction directly improves efficiency and performance.
In transportation applications, composites are increasingly used in body structures, chassis elements and interior components. Electric vehicles, in particular, benefit from lightweight composites, as reduced mass improves driving range, battery efficiency and overall safety — including fire performance.
Carbon fibre and glass fibre reinforced composites are significantly lighter than metals:
- Steel: ~7.8 g/cm³
- Aluminium: ~2.7 g/cm³
- Carbon fibre composites: ~1.5–2.0 g/cm³
- Glass fibre composites: ~1.8–2.0 g/cm³
This difference enables substantial mass reduction. In many applications, composites allow 50–75% weight savings compared to traditional metallic solutions, depending on design and material selection.
Lightweight without compromising strength
Despite their low weight, composites do not compromise on strength or stiffness. Their mechanical properties can be tailored through fibre type, orientation and laminate design, often matching or exceeding the performance of steel and aluminium.
This enables thinner structures, integrated functions and reduced part counts — all contributing to lighter, more efficient designs.
Another major advantage is corrosion resistance. Unlike steel and aluminium, composites do not rust or corrode, eliminating the need for protective coatings and significantly reducing maintenance while extending service life.
Key advantages of lightweight composite design
Significant weight reduction
Mass savings of up to 50–75% compared to traditional metals.
High strength and stiffness
Structural performance meeting or exceeding metallic solutions.
Corrosion resistance
Reduced maintenance and longer service life.
Design freedom
Complex geometries and integrated functions without added weight.