Lightweight materials include aluminum, plastics, magnesium, carbon fiber, and metal matrix composites. Using lightweight materials manufacturers can build more fuel efficient vehicles without sacrificing safety, durability and comfort. For every 10 % of weight eliminated from a vehicle's total weight fuel economy improves by seven percent. A major focus of researchers affiliated with the Partnership for a New Generation of Vehicles is to develop new lightweight, high-strength materials. Researchers are aiming to cut vehicle weight up to 40 percent - about 1,200 pounds - compared to today's average mid-sized sedan. Research must also find cost effective ways to mass produce vehicles constructed with lightweight materials.

Current aluminum technology can cut half the weight out of a conventional body structure and many manufacturers are already using it extensively. The Acura NSX sports car manufactured by Honda has a lightweight aluminum body that is 40 % lighter than a comparable steel body. Similar weight reduction is reported by Ford Motor Co. with their P2000 car. This vehicle is part of the U.S. Federal government program, Partnership for a New Generation Vehicle; it is made with about 733 pounds of aluminum as well as significant amounts of magnesium and plastics.