Aluminum: a material is changing mobility

The future of the automotive industry is lighter and more sustainable – thanks to aluminum. With a weight reduction of up to 45 percent compared to steel, it is revolutionizing vehicle design and offers a wide range of advantages in terms of efficiency, safety and sustainability. The Alumobility industry association has listed these benefits in detail in a white paper.

The main advantage of aluminum is its ability to drastically reduce the weight of a vehicle. This weight saving has an impact on all types of vehicles. Electric vehicles benefit from a longer range as less energy is required to move the lighter structure. Internal combustion engines also consume less fuel, which leads to a direct reduction in emissions.

The use of aluminum also reduces the need for large and heavy batteries in electric vehicles, which reduces the amount of material and costs in the manufacturing process. In addition, the lighter overall weight of a car leads to further savings in secondary components such as brakes and chassis, which further reduces production costs and resource consumption.

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Focus on safety

Aluminum offers a decisive advantage in terms of safety. Despite its lower weight, aluminum absorbs more energy than steel in the event of a collision, which offers occupants better protection. This disproves the widespread assumption that heavier vehicles are automatically safer. Lightweight vehicles can react faster and avoid accidents more easily, which not only protects the occupants, but also other road users such as pedestrians and cyclists. In addition, less kinetic energy is transferred to other vehicles in the event of a collision, reducing the consequences of accidents for everyone involved.

The key lies in the ability of aluminum to absorb impact energy in a controlled manner and ensure the safety of occupants. The reduction in vehicle weight leads to better vehicle dynamics and safer controllability, making it an indispensable component in modern vehicle construction.

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Sustainability and longevity

In addition to improved safety, the sustainability of aluminum also plays a decisive role. As aluminum has less density and is lighter, wear on important vehicle parts such as tires and brakes is reduced. This results in fewer particulate emissions and a longer service life for components. Another advantage is corrosion resistance: aluminum forms a protective oxide layer that makes it more resistant to environmental influences, especially in areas with high salt content or adverse weather conditions. This protective layer makes it possible for aluminum vehicles to remain in operation for longer without being exposed to the typical rust damage that occurs with steel.

In addition, aluminum is over 90 percent recyclable, making it a key material in the circular economy. The recycling process requires only a fraction of the energy compared to new production and significantly reduces CO₂ emissions. For vehicle manufacturers, this means that aluminum is not only a sustainable solution for production, but also for recycling at the end of a vehicle's life.

The combination of durability, low energy consumption and recyclability makes aluminum the ideal choice for the automotive industry and strengthens its role as the material of the future, according to the authors of the white paper.

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Cornel Mendler, Managing Director Die Casting at Bühler

About Alumobility

Alumobility describes itself as a “global ecosystem of leading aluminum and downstream technology partners supporting automotive manufacturers in the development of lighter, safer, smarter and more sustainable vehicles”. The association, based in Zurich, was founded to focus on technical studies and drive the introduction of aluminum body panels.

Just a few days ago, the Swiss technology company Bühler announced that it was joining Alumobility. Bühler brings almost 100 years of experience in the manufacture of structural components for vehicle construction and is a leader in the field of megacasting. Cornel Mendler, Managing Director Die Casting at Bühler, emphasised that the partnership aims to increase the spread of aluminium casting technology in the automotive sector and promote the development of innovative solutions.

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