The need to reduce vehicle weight is a constant in the modern automotive industry. Stricter environmental regulations, coupled with the demand for greater energy efficiency and range in electric vehicles, have pushed manufacturers and suppliers to seek lightweight solutions without compromising structural integrity, safety or productivity.
In this context, technologies such as die casting of light alloys, injection of reinforced polymers and advanced composite materials have established themselves as fundamental pillars. In Gestión de Compras, we work with OEMs and Tier 1 in projects that integrate these technologies from prototyping phases to mass production, optimizing the weight/strength ratio and guaranteeing the economic viability of the product.
Die Casting of Light Alloys
Die casting of alloys such as aluminum (AlSi9Cu3, AlSi10Mg) and magnesium (AZ91D, AM60B) allows for complex geometries with thin walls and excellent dimensional accuracy, making it a key solution in the manufacture of housings, structural supports and transmission components.
Key advantages:
- Excellent strength-to-weight ratio.
- High thermal conductivity for electronic or engine applications
- High repeatability, ideal for high volumes
- Ability to integrate ribs, stiffeners and fastening points
Common applications:
- Battery support structures in BEVs.
- Engine cases and transmission housings
- Structural components in steering and suspension
In Gestión de Compras, we work with IATF 16949 certified foundries and optimize mold design for shorter cycle times and longer tool life.
Injection of Reinforced Polymers
The use of fiber-reinforced technical polymers (PA6 + GF30, PP + talc, PEEK with carbon) has made it possible to displace metal components in multiple areas of the vehicle, reducing weight by up to 50% in certain sub-assemblies.
Technical highlights:
- Glass fiber or carbon fiber reinforcements improve specific stiffness.
- Low moisture absorption and good fatigue behavior (depending on base polymer)
- Ability to overmold metal inserts or perform overmolding on electronic components.
Typical components:
- Headlamp and bumper supports.
- Engine covers and air conditioning structures
- Fuse boxes, sensor housings, and connectors.
In addition, reinforced biopolymers are gaining presence as a sustainable alternative, especially in electric models.
From Gestión de Compras, we offer co-engineering for material selection and design validation through flow simulations (Moldflow) and thermal, acoustic or mechanical resistance tests.
Advanced Composite Materials
Composites based on thermoset matrices (epoxy, polyester) reinforced with carbon fiber or glass fiber are gaining ground, especially in high-performance segments or where the aim is to lighten the structure without sacrificing strength.
Outstanding advantages:
- High specific strength (ideal for structural parts)
- Low coefficient of thermal expansion
- Possibility of functional integration: hollow parts, internal ducts, localized reinforcements.
Limitations:
- High costs and longer cycle times (especially in RTM or prepregs)
- Complexity in recycling
- Increased reliance on manual or semi-automated processes
Key applications:
- Doors, hoods and roofs in sports automotive
- Reinforcements for A/B/C pillars
- Interior protection elements or roll-over structures.
In Gestion de Compras we have advanced process technologies such as SMC, LFT and RTM, combining design and sourcing expertise to achieve a balance between cost, performance and manufacturability.
Integrated Gestion de Compras Approach
The selection of the right technology depends on multiple variables: volume, geometry, strength, functional environment and budget. At Gestión de Compras, we approach lightweighting projects from a global perspective:
- Comparative technical-economic analysis between technologies
- Development of functional prototypes and material validations
- Supply: parts, tooling, assemblies and post-processing.
We have worked on a multitude of projects related to weight reduction, applying from traditional optimized processes to emerging technologies in electric mobility.
Conclusion
Vehicle lightweighting is a multidimensional career that requires advanced technical insight, expertise in multiple technologies and a strategic approach to the supply chain.
At Gestión de Compras, we combine these three elements to offer efficient, sustainable and customized solutions.
Are you developing lightweight components for your next model? Contact us and we will help you find the optimal solution.
