Lightweight Materials Keyvisual with Automobile

Lightweight Materials

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Lighten Up your Automotive Manufacturing and Designs

2025 Corporate Average Fuel Economy standards requiring 54.5 miles per gallon per vehicle are now just two design cycles away from taking effect.

Chemistry remains the key factor in getting the industry to this goal.

Henkel’s adhesives and functional coatings give designers the flexibility to introduce lighter materials, while meeting competing demands for increased durability and performance and reduced noise and emissions.

Automotive Engineering Blog

New Blog Post:
How Adhesives Are Helping Join New, Lighter Metals in Today's Cars

Have you ever tried to fix your child’s broken toy and found that when bonding two dissimilar materials, your conventional bonding method didn’t work? In the automotive industry, as OEMs are exploring new material choices to help meet the 2025 CAFE standards, this is a common occurrence as well.

Greg Ryba wrote this post on Aug 13, 2015

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Lightweighting Facts


Liquid sealants make it possible to join dissimilar materials like metal and plastic, while reducing material costs 4 to 5 times compared to hard gaskets.

(source: Henkel)



Zirconium oxide coatings enable an increased use of aluminum by improving corrosion prevention and decreasing sludge generation.



Structural adhesives can join dissimilar materials, while distributing stress more evenly across the joint — compared to fasteners and spot welding.


High-Damping Foam provides sound damping, while saving up to 2 kilograms of mass on doors and roofs.

(source: Henkel)



Structural adhesives enable designers to specify thinner, lighter materials while meeting strength requirements.


Resin Transfer Molding for composites enables shorter injection times — increasing volume production from 20,0000 to 30,000 per year to 200,000 to 300,000 per year. 

(source: Henkel)


The average vehicle has approximately 27 pounds of adhesives versus 18 pounds just a decade ago.

(source: Wall Street Journal)

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