FUSION Issue 1 2026 DIGITAL SINGLE PAGES - Flipbook - Page 18
ELECTRIC VEHICLE COMPOSITES MARKET
DRIVING THE NEXT
LIGHTWEIGHT INN
The global market for electric
vehicle composites is projected
to reach USD 40 billion by 2035,
expanding at a CAGR of 17.1%. As
automakers accelerate their shift
towards sustainability, the demand
for lighter, stronger materials is
reshaping how electric vehicles are
designed and produced.
A market in motion
The Electric Vehicle (EV) Composite Market,
valued at USD 7.05 billion in 2024, is forecast
to grow rapidly over the next decade, reaching
USD 40 billion by 2035. This remarkable
trajectory reflects the automotive industry’s
continuing transformation towards sustainable,
high-performance mobility.
As manufacturers face mounting pressure to
extend driving range and reduce emissions,
composite materials such as carbon fibre and
glass fibre are becoming integral to vehicle
construction. Their lightweight nature and
superior strength help offset the considerable
weight of electric powertrains, improving
overall efficiency without compromising
durability or safety.
Composites are now found throughout EVs,
from body panels and chassis components
to battery enclosures, interior structures,
and even powertrain housings. This growing
versatility underscores their importance in
enabling the next generation of cleaner, more
intelligent mobility.
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The forces behind the growth
Challenges along the road
Several converging factors fuel the EV
composites boom. Consumer awareness of
sustainable transport continues to rise, while
stringent emission regulations and government
incentives worldwide are encouraging
automakers to invest in lighter, more efficient
vehicle designs.
While the outlook is positive, the path to
widespread adoption is not without obstacles.
High material costs, particularly for carbon fibre,
and complex fabrication processes remain barriers
for lower-cost EV manufacturers. Recycling
and end-of-life management of composite
components also present ongoing challenges.
At the same time, technological advances
in manufacturing processes – including
automated fibre placement and 3D printing, are
helping reduce production costs and broaden
adoption. These advances make composite
materials increasingly viable for large-scale
vehicle manufacturing, bridging the gap
between performance and affordability.
However, industry research and development
are steadily addressing these concerns. Efforts
to improve resin systems, develop hybrid
materials, and automate production are making
composites more accessible. The introduction
of smart composites, materials embedded with
sensors to monitor performance and structural
integrity, is another example of how innovation
is helping overcome current limitations.
Another key development is the growing
adoption of thermoplastic composites. Unlike
traditional thermoset materials, thermoplastics
are recyclable, easy to mould, and well-suited
to the high production volumes associated
with mainstream EV models. Combined with
the emergence of bio-based and recyclable
composites, this trend supports the global
automotive industry’s sustainability objectives.
