Formulated to provide longer lasting protection, to preserve the aesthetics and tactility of beautiful surfaces.

In recent years, the trend towards lightweighting has taken root in the automotive industry. This is the process of designing and manufacturing vehicles with lighter materials to reduce weight, improve fuel efficiency, and minimize emissions. The adoption of lightweighting techniques and materials has become a key strategy for automakers looking to meet increasingly stringent fuel efficiency standards and reduce their environmental footprint.

One of the primary methods used to achieve lightweighting is through the use of advanced materials such as carbon fiber, aluminum, magnesium and high-strength steels. These materials offer significant advantages over conventional metals, particularly in terms of weight reduction without compromising strength and stiffness. By integrating these lightweight materials into vehicle components such as body panels, chassis components, and powertrains, automakers have been able to produce vehicles that are lighter, more fuel-efficient, and greener without sacrificing performance or safety.

As more consumers become environmentally conscious and fuel prices continue to rise, the demand for lightweight vehicles will only increase. By continuing to invest in researching and deploying lightweight materials and manufacturing processes, the automotive industry is poised to meet this demand and stay ahead of the curve in the coming years. With innovative approaches to design, manufacturing, and material selection, the future of the industry is sure to be bright.

Not only does NANOKOTE manufacture ultra-thin anti corrosion coatings for light metals but we also can now produce opaque coatings of only 2 micron in thickness and only 7 microns in thickness for opaque gloss finishes.

These novel coating materials can be applied many automotive surfaces (both interior and exterior applications). Metal surfaces such as Aluminum and magnesium can be coated along with both rigid and flexible plastics such as ABS, PP and TPO. Specialised applications on metalized plastics are also possible.

Lightweight materials

Typical components


Shock absorber, brake, piston, tank, wheel rim, fender, roof, door, bumper, heat insulator, handle, piping, steering component, conrod, rotor, suspension component, bonnet, chassis, spoke, valve, gas cylinder, seat frame

Light alloys


Engine block, steering wheel frame, seat frame, instrument panel, wheel rim, cylinder head, clutch case, cylinder block, transmission case, lower crankcase, intake manifold, air intake system, steering link bracing, oil pump body, camshaft drive chain case, gear control housing, bracket


Connecting rod, engine valve, spring, intake valve, wheel, turbocharger, exhaust system, muffler, body frame, engine rocker arm, suspension component, engine piston pin, fastener, lug nut, door penetration beam, car stop bracket, brake caliper piston, pin bolt, pressure plate, shift button, clutch circle, fuel tank, fuel cell separator.


Frame, body, crash zone, pillar, roof rail, door beam, seat frame, front side member, bumper reinforcement, roof bow, rocker, cross member, seat track


Bumper beam, body, frontal bonnet, seatback. door panel, lining, insulation, cargo area, instrumental panel, body panel, dashboard, windshield, wheel box, roof cover, floor tray, pillar, rear storage shelf, hood

Practical example for an EV production plant
producing 400,000 vehicles annually.

Most vehicles contain 25-30kg of coatings in different forms on varying array of substrates. Just taking the external body as an example.


Uncoated weight (g)

Coated weight (g)

Coating weight (g)

Dry film thickness (Eddy Current)

10 mm x 10 mm x 0.97 mm Aluminum test price





Opaque finish with:
Semi gloss – 2 micron DFT
Gloss – 7 micron DFT
Vehicles manufactured annually : 400,000

This works out to be 21.9 g/m2 at a dry film thickness of 7 micron.

If we assume 8 sqm of coated aluminum on an average vehicle for the purpose of an example (in reality the area can vary from 5 – 15 sqm depending on the car model) this works out at 175.2 gm per vehicle.

Comparatively, traditional paint systems for coating aluminum on vehicles will result in 6kg in coating weight.

Weight saving on 8 sqm of aluminum body coating with NANOKOTE technology : 5.8kg per vehicle

For an EV this translates into 100,000,000 km per year in additional efficiency across the vehicles produced

Weight savings coating materials along with low temperature curing techniques are important but only if the performance characteristics of the coatings meet specification requirements. So very importantly also is that these coatings meet specification requirements which for most automotive applications will involve the following tests,

Properties desired

Metal exterior

  • Solvent resistance
  • Coating hardness
  • Adhesion
  • UV transmission of clearcoat
  • Scratch and mar resistance
  • Abrasion resistance
  • Stone chip resistance
  • Water jet resistance
  • Heat resistance
  • Moisture resistance
  • Thermal shock resistance
  • Water immersion
  • Chemical resistance
  • Acid resistance
  • Cyclic corrosion
  • Filiform corrosion
  • Accelerated weathering
  • Natural weathering
  • Environmental exposure

Plastic exterior

  • Solvent resistance
  • Film micro hardness
  • Mandrel bend test
  • Impact resistance
  • UV transmission of clearcoat
  • Adhesion
  • Chip Resistance
  • Scratch resistance
  • Thermal shock
  • Water jet resistance
  • Chemical resistance
  • Acid resistance
  • Humidity resistance
  • Natural weathering
  • Artificial weathering
  • Heat resistance