24 - 08 - 2026

Indian automotive sector in the race to make vehicles lighter

Driven by emissions regulations, electric vehicle (EV) adoption and emerging supply opportunities across the globe, Indian automotive component sector is undergoing a paradigm shift, the biggest in decades.

The engineering shift, termed lightweighting, aims to reduce the weight of an automotive by using advanced materials, complex techniques and state-of-the-art technologies. While reducing weight will help in improving fuel efficiency, manufacturers must maintain structural integrity, safety, and overall driving performance of the vehicle.

This is also expected to be a windfall for Indian auto component makers, who are eyeing a massive ₹9,000–10,000 crore addressable market in vehicle lightweighting by FY31.

At present, the focus of lightweighting is primarily on heavy structural chassis parts, including control arms, links, torsion beams, and engine subframes.

Component makers are replacing standard steel with high-strength low-alloy steel, aluminium extrusions, magnesium alloys, and high-performance polymers. At present, the focus is primarily on heavy structural chassis parts, including control arms, links, torsion beams, and engine subframes.

Advanced manufacturing methods such as hollow forging and hydroforming allow suppliers to craft components that are significantly lighter yet stronger than their predecessors.

The Math

Weight is the single biggest enemy of efficiency. In traditional internal combustion engine vehicles, every kilogram shed translates directly into lower fuel consumption and reduced tailpipe carbon emissions. For electric vehicles (EVs), mass management is even more crucial. Because EV battery packs add substantial dead weight to the chassis, automakers must strip mass from structural parts to maintain an acceptable driving range on a single charge.

The primary catalyst for this transition is the rollout of tighter Corporate Average Fuel Consumption norms. These regulations hold vehicle manufacturers accountable for the aggregate fuel efficiency of their entire fleet, forcing them to re-engineer core platforms. Additionally, as modern cars add heavy technology, safety features, and infotainment systems, lightweighting underlying structural parts balances out the added weight of these consumer features.

Global Supply Ties

To capture this growing market, domestic component manufacturers are looking to bridge the technology gap. Domestic players are entering joint ventures and technical collaboration agreements with specialised foreign engineering firms. Securing global design expertise enables local players to manufacture high-spec, lightweight subframes domestically positioning them not only to supply domestic assembly lines, but also to win bigger export orders from global automakers seeking cost-effective supply chains.

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