BYD looks up at the U8L, with an aluminum frame that is 56 kilograms lighter than steel. The number of parts has been reduced from 251 to 119, and the torsional stiffness has increased by over 50%.

The overall sales of automotive aluminum profiles have increased, and lightweight projects have branched out.

The average aluminum consumption of pure electric vehicles has reached 240 kilograms, more than twice that of traditional fuel vehicles. The aluminum consumption in China’s automotive industry is expected to reach 8 million tons by 2026, a year-on-year increase of over 20%.

‘Every kilogram you lose, every kilometer you run’ – this is not a slogan, it is the survival rule of the new energy vehicle industry.

In this lightweight revolution, aluminum is undoubtedly one of the protagonists.
Why has aluminum become the protagonist? Because weight loss is about battery life

Traditional fuel vehicles can reduce fuel consumption by 0.3-0.6 liters per 100 kilometers for every 100 kilograms reduction in vehicle weight.

In new energy vehicles, the benefits of weight reduction are amplified more directly.

For electric vehicles, where battery costs still account for one-third of the total vehicle cost, lightweighting means running farther with fewer batteries, which is the core path to directly reduce costs and increase efficiency.

Aluminum, with a density only one-third that of steel, has high specific strength, good processability, corrosion resistance, and recyclability.

It is not as expensive as carbon fiber and can achieve significant weight reduction effects – aluminum has become the optimal solution for car companies to balance cost and performance.

From the body and chassis to the battery pack and cooling system, aluminum is replacing steel comprehensively and becoming the main material for the “lightweight revolution” of new energy vehicles.
Aluminum frame from ‘impossible’ to ‘benchmark’

In June 2026, BYD looked up at U8L and presented an “aluminum answer sheet” to the industry.

This large off-road SUV features aviation grade 6 Series and 7 Series aluminum alloy frames, jointly developed by BYD and Hangte.

The results are stunning:

Weight 56 kilograms lighter than similar steel frames

What does a weight loss of 56 kilograms mean?

For a large SUV, this is equivalent to being able to run a longer range even after carrying the weight of an adult.

Aluminum is capturing the ‘core stronghold’ that was once only held by steel.

New energy is’ eating up ‘traditional production capacity

A set of data reveals the scale of the lightweight revolution:

The average aluminum consumption of pure electric vehicles is 240 kilograms, while traditional fuel vehicles only consume 120-150 kilograms, doubling

High end car models use over 500 kilograms of aluminum

The expected aluminum consumption in China’s automotive industry in 2026 is 8 million tons, a year-on-year increase of over 20%

Only in the field of new energy vehicles, the annual demand for aluminum materials is about 2.7 million tons

Where did all this aluminum go?

Body structural components: collision beam, threshold beam, all aluminum frame – U8L is a typical example

Battery system: battery tray, cooling plate, thermal management system valve body – the “rigidity+thermal conductivity” essential for each vehicle

Chassis and wheel hubs: control arms, subframe, aluminum alloy wheels – aluminum instead of steel is being fully deployed

The transportation industry has become the largest consumer of aluminum, and the proportion of aluminum related to new energy is expected to soar from 10% in 2021 to over 25% in 2026.

Aluminum is not “chosen”, but “needed”.