Latest Body-in-White Trends

In the ever-evolving world of automotive manufacturing, Body-in-White (BiW), the stage where a vehicle's sheet metal components are welded together to form the vehicle's skeletal structure, has become a hotbed of innovation, writes Ashish Bhatia.

- Ashish Bhatia

With increasing pressure from regulators and customers alike to produce safer, lighter, and more fuel-efficient vehicles, BiW suppliers have stepped up their game. From new age materials to advanced joining technologies and modular architectures, key suppliers across India and Europe are spearheading transformative changes. The latest BiW trends, spotlight major players like Gestamp and examine how Indian and European manufacturers are competing, collaborating, and preparing for the future of vehicle manufacturing.

Light weighting

One of the dominant themes in BiW evolution is light weighting. It directly influences fuel economy and tailpipe emissions in ICE vehicles, while also impacting the range and performance of EVs. Indian players like JBM Auto and Bharat Forge have increasingly focused on the development and integration of lightweight materials, such as Advanced High-Strength Steels (AHSS), boron steels, and aluminium alloys. These materials help reduce vehicle weight without compromising on structural integrity or crash safety.

European BiW specialist Gestamp, with its strong engineering base and global footprint, is pushing the envelope on light weighting. The company has deployed hot stamping extensively, a process that forms ultra-high-strength steel components under extreme temperatures. This technology allows for complex part geometries with improved safety performance, and is now being localised at scale in India to support domestic OEMs. Gestamp’s Pune and Chennai facilities are now manufacturing BiW components for Indian and global platforms, integrating high-tech joining techniques like laser welding, tailor-welded blanks, and riveting, while focusing on cost competitiveness for emerging markets.