Car Body: Structure, Materials, Classification & Use Notes

Car body is a structural system that covers and protects the vehicle's internal components. This is one of the most important parts of the car, playing the role of protecting internal details, ensuring safety for passengers and creating an aesthetic appearance for the car.

The automobile body system includes main parts such as chassis, shell panels, door frames, pillars, vehicle glass, reinforcing details and a number of other body parts. In addition to protecting the internal components, the body shell also helps the vehicle operate stably, reduces air resistance and ensures safety for passengers in the event of a collision.

Common materials for manufacturing bodies include steel, aluminum, carbon fiber and composite materials. Each type has its own advantages and disadvantages in terms of durability, weight, corrosion resistance and production costs.

Based on design, car body types include Sedan, Hatchback, SUV, Coupe, Convertible, Pickup, MPV,... each body type brings different experiences to users.

According to Dr. Mary Barra, CEO of General Motors: body repair and replacement costs account for 60-70% of total car repair costs. Therefore, mastering knowledge about vehicle bodywork is essential to optimize operating costs and prolong the life of the vehicle.

In particular, if you want to maintain the beauty and durability of your car body, you need to: use it properly, repair it promptly and maintain it periodically.

Let's explore details through the following article!

What is the role of the car body?

The car body is the outer shell of the vehicle, including all fixed, non-moving parts such as the chassis, doors, hood, trunk and has the main function of protecting the passenger compartment, engine, drive system from external influences.

The car body is not simply an outer metal shell, but a complex structural system, carefully calculated to ensure:

• Stiffness: Helps the vehicle stay stable when operating, especially at high speeds or when cornering sharply.
• Shock absorption ability: Protects passengers in the event of a collision by absorbing and dispersing impact force.
• Aerodynamics: Reduces air resistance, optimizes operating performance and fuel economy.
• Aesthetics: Create a unique appearance and style for each car model, expressing the owner's personality.

What is the Structure of a Car Body?

The parts that make up the car body include the chassis, body panels, glass, doors and other reinforcing details.

1. Chassis

The chassis is the "backbone" of the car, the support for all other parts such as the engine, gearbox, suspension system... There are two main types of chassis: body-on-frame and body-on-frame. unibody frame.

2. Shell plate

The shell is a direct protection layer for the passenger compartment and internal parts of the vehicle from the impact of the external environment such as rain, sun, dust, scratches, etc.

Classify shell panels by location:

• Hood panel.
• Front/rear door panels.
• Hood cover.
• Trunk lid.
• Front/rear fenders.
• ...

3. Door frame

The door frame is the reinforcing part inside the car door, usually made from high-strength steel, with good strength and shock absorption. In the event of a side collision, the door frame will absorb the impact force, minimizing the risk of injury to passengers.

4. Pillar

Pillars are load-bearing steel bars arranged in strategic positions on the vehicle frame such as:

• Column A: Located between the windshield and front door.
• Column B: Located between the two car doors.
• Column C: Located behind the rear window.

This part has the role of supporting the hood, maintaining the shape of the passenger compartment in the event of a collision and preventing the car from being crushed, protecting the living space for the people sitting inside. Pillars are often made from boron steel - a steel with very high hardness and tensile strength, helping to absorb impact forces extremely well.

5. Car glass

Types of vehicle glass such as windshields for panoramic visibility, automatic anti-glare rear glass, soundproof window glass... also contribute to perfecting the car body.

6. Reinforcement details

To increase the rigidity and bearing capacity of the shell, it is necessary to add many other reinforcing details such as horizontal beams, longitudinal beams, reinforcing plates...

These parts are often made from high-strength steel or cast aluminum, arranged in key positions on the vehicle frame, helping to disperse impact forces more evenly, minimizing body deformation.

7. Other body parts

In addition to the main parts, the car body system is also completed by exterior accessories such as rearview mirrors, modern LED headlight clusters, luxurious chrome-plated door handles, and rain sensor wipers. automatic, aerodynamic fenders...

What Material Are Car Body Shells Made From?

From traditional steel, the automotive industry has been witnessing the rise of new materials such as aluminum, carbon fiber, composite materials... opening a new era for car bodies: super light, super durable and environmentally friendly.

1. Steel

As the most popular material in automobile production since the beginning, steel still holds an important position in the car industry thanks to its low price, ease of processing and many choices of steel grades with unique mechanical properties. different reasons.

Steel classification in automobile production:

• Cold-rolled steel: Produced by cold rolling hot steel plates at room temperature, has a smooth surface, high precision, often used to make vehicle tire panels.
• Hot rolled steel: Produced by hot rolling steel plates at high temperatures, has higher durability than cold rolled steel, often used to make chassis, beams, and pillars.
• High-strength steel: Has higher tensile strength and hardness than conventional steel, helping to reduce vehicle weight while still ensuring safety.
• Alloy steel: Added other elements such as manganese, silicon, chromium... to improve mechanical properties, corrosion resistance, heat resistance...

For example:

• The Toyota Corolla's chassis uses high-strength steel up to 590 MPa, helping to reduce vehicle weight by 17kg compared to the previous generation.
• The Honda Civic's A-pillar is reinforced with 1500 MPa boron steel, increasing its bearing capacity and protecting passengers in the event of a collision.

2. Aluminum

Aluminum is a material that is about 30% lighter in weight than steel but still ensures rigidity and good corrosion resistance. However, the production cost of aluminum is higher than that of steel, requiring more complex manufacturing technology.

Common types of aluminum alloys:

• 6xxx series: Contains magnesium and silicon, has good weldability, is easy to process, and is often used to make vehicle tire panels.
• 7xxx series: Contains zinc, magnesium and copper, has the highest durability among aluminum alloys, often used to make vehicle frames and load-bearing parts.

For example:

• Ford F-150, the world's best-selling pickup truck, has switched to using an aluminum alloy body since 2015, helping to reduce vehicle weight by 317kg, increasing fuel economy and cargo capacity.
• Audi A8, the luxury sedan of the German brand, uses the Audi Space Frame (ASF) chassis made from aluminum alloy, magnesium and carbon fiber, helping to reduce vehicle weight by 40% compared to a traditional steel chassis.

3. Carbon Fiber

Carbon fiber is a super light and super durable material, 5 times lighter and 10 times stronger than steel. However, the cost of producing carbon fiber is very high, the manufacturing process is complex, and requires advanced technology.

This material is used to make supercar and racing car bodies to reduce vehicle weight, increase speed and performance. In addition, it is also used to make some details on luxury cars such as hoods, spoilers, mirror covers...

For example:

• Bugatti Chiron, a supercar with a record speed of 490 km/h, uses a monocoque body made entirely from carbon fiber, helping to reduce the car's weight to only 1995kg.
• The BMW i8, a hybrid sports car, uses a Life Module chassis made of carbon fiber reinforced plastic (CFRP), which helps reduce vehicle weight by 50% compared to a steel chassis.

4. Composite materials

Composite materials are a combination of two or more different materials, forming a new material with superior properties than the structural components. In the automobile industry, composite materials are often used to make body panels, front bumpers, rear bumpers, hoods, etc.

Advantages of composite materials:

• Light-weight.
• Durable.
• Good corrosion resistance.
• Good soundproofing and heat insulation.
• Easily create complex shapes.

For example, the Chevrolet Corvette C8, an iconic American sports car, uses Sheet Molding Compound (SMC) to make the car's body, helping to reduce weight and increase rigidity.

How to Classify Car Body Shells?

Car bodies are classified based on style, each body style brings different experiences to the user.

1. Sedan

Traditional design with 4 doors, 3 separate compartments (engine compartment, passenger compartment, luggage compartment); Sedan is the ideal choice for those who love luxury, elegance and spacious interior space.

For example: Toyota Camry, Honda Accord, Mazda6, Mercedes-Benz C-Class, BMW 3 Series...

2. Hatchbacks

Possessing a sporty design with a short rear end, the rear door opens upwards, and folds the rear seats to expand the luggage compartment; Hatchback is suitable for those who love youthfulness, dynamism and frequent urban mobility.

For example: Ford Fiesta, Hyundai i20, Kia Morning, Toyota Yaris, Honda Jazz...

3. SUV (Sport Utility Vehicle)

SUV has a strong design, high chassis, suitable for moving on many terrains. This is the top choice for those who love strength, personality and want to conquer new roads.

For example: Toyota Fortuner, Hyundai Santa Fe, Mazda CX-5, Ford Everest, Honda CR-V...

4. Coupe

With a sporty 2-door design, low hood, focusing on performance; Coupe is the choice for those who are passionate about speed, sporty style and want to express their strong personality.

For example: Audi TT, BMW Z4, Porsche 911, Toyota Supra, Ford Mustang...

5. Convertible (Open-top car)

Luxurious design, the hood can be opened/closed electrically, so the Convertible brings an exciting, liberal driving feeling, suitable for traveling in nice weather conditions.

For example: BMW 4 Series Convertible, Mercedes-Benz C-Class Cabriolet, Audi A5 Cabriolet, Mazda MX-5 Miata...

6. Pickup (Pickup truck)

Aggressive design, rear cargo box; Pickup is the right choice for those who need a multi-purpose vehicle, capable of carrying goods and moving flexibly.

For example: Ford Ranger, Toyota Hilux, Mitsubishi Triton, Nissan Navara, Isuzu D-Max...

7. MPV (Multi-Purpose Vehicle)

MPV has a spacious design, usually with 3 rows of seats, suitable for large families or those who need spacious interior space.

For example: Toyota Innova, Mitsubishi Xpander, Suzuki Ertiga, Kia Sedona, Hyundai Solati...

How to Preserve the Lasting Beauty of the Car Body?

To keep your car's body shiny and durable over time, you need to: use it properly, repair it promptly and maintain it periodically.

1. "Prevention is better than cure" - use properly

When using a car, it is necessary to comply with the following requirements to effectively protect the body:

• Wash your car properly: You should wash your car every 1-2 weeks, using specialized car wash solution and soft towels to avoid scratches on the paint. Avoid washing your car directly in the sun, because high temperatures will cause water to evaporate quickly, leaving stains on the paint surface.
• Store your car in a cool, dry place: Avoid parking your car in strong sunlight for long periods of time, because UV rays in the sun will fade the paint color and reduce the car's shine. You should park your car indoors or in a covered place to better protect the paint layer.
• Use protective measures: Apply heat-insulating film to car windows to limit the impact of UV rays, and apply nano ceramic coating to the body shell to create a protective layer against scratches, water and dirt.

2. Timely handling of damages

Here are some common damages related to car bodywork and how to handle them:

• Treating paint scratches: Depending on the severity of the scratch, you can treat it yourself by using a scratch removal pen, polishing cream or taking the car to a reputable garage to have it repainted.
• Repairing dents: For mild dents, you can use the straightening technique with a torch or hot air gun. With severe dents, it is necessary to repair, weld or replace the cover with a new one.
• Replace the shell: When the shell is severely damaged and cannot be repaired, you need to replace it with a new one. You should choose genuine spare parts or from reputable suppliers to ensure quality and compatibility with the vehicle.

3. Periodic maintenance

Car body maintenance solutions include:

• Polishing: Helps remove scratches and restore shine to the paint layer. You should polish your car every 6 months or once a year depending on usage conditions.
• Nano ceramic coating: Creates a sturdy, scratch-resistant, water- and dust-resistant protective layer, helping to preserve the beauty of the car body. Nano ceramic coating should be done every 1 year or every 2 years.
• Check and maintain metal parts: Check, clean, and anti-rust paint for metal parts such as chassis and chassis to prevent rust and ensure vehicle durability.

Some Questions Related to Car Body

1. Does the thickness of the car cover affect the car's noise-canceling ability?

Shell thickness is a factor, but not the only factor that determines the car's soundproofing ability. Normally, a thicker shell will help reduce outside noise from entering the cabin better.

However, other factors such as soundproofing materials, door gasket design, soundproof windshield... also play an equally important role.

2. What types of materials have potential to make car bodies in the future?

Some other potential body materials (in addition to steel, aluminum, carbon fiber) include:

• Graphene: Super light, super durable, good electrical conductivity, can be used to make electric vehicle bodies, helping to reduce weight and increase operating range.
• Magnesium alloy: Lighter than aluminum, has good vibration resistance, and has the potential to replace aluminum in the future.
• Self-healing material: Capable of self-healing small scratches, helping to prolong the life of the body.

3. What advantages does powder coating have over conventional paint?

Powder coating uses electrostatic attraction to adhere the paint layer to the surface of the material, which is then passed through an oven to form a hard paint layer.

Advantages of powder coating:

• High adhesion, more durable than regular paint.
• Less paint loss, more environmentally friendly.
• Creates an even, beautiful paint layer with few errors.

4. What is auto body insurance?

Auto body insurance is a type of insurance that compensates for physical damage to the vehicle caused by an accident, including the following cases:

• Collision with another vehicle.
• Rollover.
• Fire, explosion.
• Natural disasters, storms and floods.

5. Why should you buy auto body insurance?

Reasons to buy Auto body insurance the:

• Comprehensive protection for your beloved driver: Car body insurance acts as a solid shield, covering and protecting the vehicle from most common risks such as collisions, natural disasters, theft...
• Save significant repair costs: You only need to pay a reasonable annual fee, the rest will be taken care of by the insurance company, helping you feel more secure against all risks.
• Increase the value and liquidity of the car: Dealers and buyers will feel more secure when choosing a car with a clear and complete insurance history.
• Peace of mind when driving: Once you have body insurance, you will feel more secure and confident when driving, no longer worrying about collisions, scratches or even theft.
• Quick compensation procedures: With reputable insurance companies, the compensation process is always simplified and shortened to the maximum. You just need to provide complete documents and information, the insurance company will quickly assess and pay compensation as soon as possible.

6. Where should a reputable car be maintained and repaired?

With more than a decade of experience in the field of car care, repair and maintenance, Thanh Phong Auto Proud to become the name that car owners in Ho Chi Minh City trust and choose first when they need to paint, car body paint.

Strengths of Thanh Phong Auto:

• Check and evaluate the overall vehicle condition thoroughly to come up with the most optimal solution.
• The service workshop is invested in the most advanced machinery and technology today.
• Committed to using only genuine spare parts, imported directly from reputable manufacturers.
• Thanh Phong Auto's staff is well-trained in both expertise and communication and service skills.
• Professional car maintenance and repair process, repertoires.
• Provide public, transparent and detailed quotes to customers in advance.

With outstanding quality, competitive prices, thoughtful after-sales service and warranty; Thanh Phong Auto Confidence is the ideal destination, bringing peace of mind and maximum savings to customers.