Lightweighting is a concept in the auto industry about building cars and trucks that are less heavy as a way to achieve better fuel efficiency, battery range, acceleration, braking and handling. ^{[1] [2]} In addition, lighter vehicles can tow and haul larger loads because the engine is not carrying unnecessary weight. ^[3] Excessive vehicle weight is also a contributing factor to particulate emissions from tyre and brake wear. ^{[4] [5]}

Carmakers make body structure parts from aluminium sheet, aluminium extrusions,press hardening steel, carbon fibers, windshields from plastic, and bumpers out of aluminum foam, as ways to lessen vehicle load. ^[6] Replacing car parts with lighter materials does not lessen overall safety for drivers, according to one view, since many grades of aluminium and plastics have a high strength-to-weight ratio; and aluminum has high energy absorption properties for its weight. ^[6]

The search to replace car parts with lighter ones is not limited to any one type of part; according to a spokesman for Ford Motor Company, engineers strive for lightweighting "anywhere we can." ^[7] Using lightweight materials such as plastics, high strength steels and aluminium can mean less strain on the engine and better gas mileage as well as improved handling. ^[8] One material sometimes used to reduce weight for structures that can accept the cost premium is carbon fiber. ^[9] The auto industry has used the term for many years, as the effort to keep making cars lighter is ongoing. ^[2]

Another common material used for lightweighting is aluminum. ^[10] Incorporating aluminum has grown continuously to not only meet CAFE standards but to also improve automotive performance. A light weighting magazine finds: "Even though aluminum is light, it does not sacrifice strength. Aluminum body structure is equal in strength to steel and can absorb twice as much crash-induced energy." ^[11] The use of aluminium for lightweighting can be limited for the higher strength grades by their low formability - and in response to this forming challenge new techniques such as roll forming and hot forming ( Hot Form Quench) have been introduced in recent years.

Many other materials are used to meet lightweighting goals. ^[12] Cost of lightweighting, and increasingly sustainability of materials, is becoming an issue in solution selection - with the viable cost increase of a part per kilogram saved being between $5 and $15, ^[13] depending on the price point and performance needs of the vehicle.

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