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BYD says new aluminium frame cuts weight and improves strength in Yangwang U8L

EDITED BY : 2MINS READ

cars

Stock image for referential purposes only

Chinese electric vehicle maker BYD says its new aluminium frame technology has reduced vehicle weight while improving structural performance in the Yangwang U8L SUV.

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According to the company, the frame is around 56 kg (more than 120 lbs.) lighter than a comparable steel structure and has passed a 12-tonne lifting test.

The U8L project focused on developing a full-size vehicle frame capable of delivering high strength and corrosion resistance without the weight penalty associated with conventional steel-intensive designs.

BYD engineers evaluated multiple material options, including advanced steel and titanium alloys, before selecting aerospace-grade 6-series and 7-series aluminium alloys.

A key part of the project was the adoption of a low-pressure casting process jointly developed with aerospace supplier Hangte.

Unlike conventional casting methods, the process gradually pushes molten aluminium upward into the mould under low pressure, reducing turbulence and internal voids. According to BYD, this produces a denser structure with fewer defects in the finished component.

Explore: The most comprehensive and forward-looking industry-focused report – Global Bauxite & Alumina Market Forecast to 2036: Supply–Demand, Trade Flows & Price Outlook

The company said the technology has previously been used in aerospace manufacturing and is now being applied to vehicle frame production.

BYD added that the new manufacturing process has simplified vehicle construction. The total number of frame components was reduced from 251 to 119, while 67 rear-frame parts were consolidated into a single casting.

At the same time, weld length was reduced from about 100 metres to 9 metres, potentially lowering fatigue and deformation points over the vehicle’s lifespan.

BYD said the structure is the first integrated low-pressure cast vehicle frame developed in China for a large vehicle platform.

The company also claimed the frame delivers more than 50% higher torsional rigidity than similarly sized SUV frames while significantly reducing overall weight.

The development reflects the growing use of aluminium in vehicle manufacturing as automakers seek to improve efficiency, range and structural performance without compromising safety or durability.

Explore our e-magazine ALuminium LeaderSpeak 2026 for the latest industry insights and trends

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