Mazda’s Weight-Saving Quest: Exploring Carbon Fiber for Future Models

Mazda prioritizes weight reduction in its vehicles, exemplified by the lightweight MX-5 Miata, tipping the scales under 2,400 pounds through meticulous gram-shaving tactics. However, as the automotive landscape evolves, the Japanese manufacturer is delving into novel materials for potential upcoming releases.

A recent patent granted to Mazda elucidates the methodologies it aims to employ in crafting such a vehicle. While the patent doesn’t specify the model beyond its four-door configuration, indications suggest a departure from the realm of sports cars, possibly hinting at a sedan. This exploration aligns with Mazda’s endeavor to combat weight gain amid the electrification era.

Recent patents disclose Mazda’s vigorous endeavors in hybrid and full EV development, ventures inherently burdened by increased mass compared to traditional internal combustion engine (ICE) vehicles. To counterbalance this, Mazda is keenly focused on leveraging carbon fiber composites to lighten the body and chassis—the second heaviest components after the drivetrain. The patent outlines a method to fabricate a “quasi-isotropic” material, engineered to exhibit strength in all load-bearing directions. Additionally, diverse cross-sectional profiles are proposed for various structural elements like roof-supporting pillars, frame rails, and crash bumpers.

Notably, Mazda isn’t embarking on this journey alone. The patent collaboration involves Nippon Steel Chemical & Material Co., Ltd., indicating Mazda’s partnership with an experienced entity in carbon fiber structure development.

While the fruition of a carbon-chassis Mazda remains uncertain, the insights into the company’s behind-the-scenes research are intriguing. It raises the prospect of Mazda introducing a hybrid or electric sedan boasting a carbon frame, potentially offering a significant weight advantage over competitors. The timeline for such innovations, however, remains undisclosed, leaving enthusiasts eagerly awaiting Mazda’s next move in this groundbreaking pursuit.

Photo Source: SMI Composites