Composite-material spring technology has been successfully commercialized, enabling automakers to achieve weight reductions of up to 85% through lightweight design.

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The China Composites Industry Association has released industry‑wide technological updates, highlighting the large‑scale deployment of fiber‑reinforced polymer (FRP) and carbon‑fiber reinforced polymer (CFRP) composite springs in vehicle applications. These advanced springs have fundamentally addressed the traditional drawbacks of steel springs—high weight and excessive noise—emerging as a core lightweighting solution for new‑energy vehicle manufacturers.

Data show that carbon‑fiber leaf springs have a density only one‑quarter that of steel and a specific strength five times higher. Volvo and several domestic new‑energy vehicle manufacturers have already adopted composite suspension springs, reducing the weight of a single set from 15 kg to under 2 kg—a 85% weight reduction—while simultaneously boosting vehicle range by 6%–10%. Moreover, the material is non‑magnetic and offers excellent damping performance, significantly cutting chassis vibration and noise and meeting the quiet‑operation requirements of electric vehicles.

On the manufacturing side, fully automated fiber‑winding and pultrusion production lines are gradually becoming widespread. Leading spring manufacturers have integrated vacuum heat treatment and laser‑based full‑inspection of contour dimensions, addressing challenges such as fatigue cracking and interfacial bond strength in composite materials. Industry experts note that composite springs currently cost 5–8 times more than steel springs; however, with the scaling up of production lines and the localization of raw materials, costs are expected to decline by 40% by 2028, enabling broad adoption across passenger vehicles, rail transit, and vibration‑damping applications in construction machinery.

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