LONDON, 2025 — Claritas Intelligence has published its global market report on EV lithium battery structural parts, estimating the market at USD 11.8 billion in 2025 and projecting — under the firm's base case — growth to USD 27.6 billion by 2033, a compound annual growth rate of 11.2% over the 2025–2033 study period.
The structural architecture shift from modular packs to cell-to-pack (CTP) and cell-to-chassis (CTC) designs is the most consequential demand driver the report identifies. Claritas estimates CTP/CTC penetration at approximately 28% of BEV production volume in 2025, rising to 55% by 2030. The commercial logic is counterintuitive: consolidating part counts does not shrink the addressable market. Outer trays, longitudinal beams, and thermal-plate assemblies in a CTP configuration bear crash-load paths previously absorbed by sub-module frames, commanding 30–60% unit-price premiums over modular equivalents. CATL's CTP 3.0, BYD's e-Platform 3.0 CTC, and Tesla's bonded 4680 structural pack are each in validated production — and the report projects CTC alone could capture 18% of new BEV structural-parts value by 2030. Gigacasting reinforces the same dynamic: Tesla's deployment of 6,000-tonne and 9,000-tonne gigapresses reduces underbody part counts by 70-plus components per vehicle, a benchmark Volkswagen, Toyota, and Hyundai are each pursuing, with battery-tray integration following naturally.
Regulatory pressure adds a non-discretionary demand floor on two continents. EU Regulation 2019/631, as amended in 2023, mandates a 55% CO2 reduction for new passenger cars by 2030 and 100% by 2035; OEM non-compliance penalties of EUR 95 per g/km excess CO2 per vehicle make BEV volume ramps financially compulsory, not aspirational. The UK ZEV Mandate targets 80% zero-emission new car sales by 2030. In North America, IRA Section 30D consumer credits of up to USD 7,500 and Section 45W commercial-vehicle credits are pulling forward BEV demand, while the FEOC exclusion provisions — effective 2025 — simultaneously pressure Tier 1 suppliers to establish domestically sourced structural-parts supply chains to preserve credit eligibility for their OEM customers. The report identifies IRA FEOC rules as the single largest near-term disruption risk for Asian-dominated supply chains, forcing OEMs to audit battery-module housings, end-plates, and thermal-management components for Chinese-entity content.
Asia Pacific commands approximately 58% of global market share in 2025, and the region is simultaneously the largest and fastest-growing geography in the report's model. China alone accounts for approximately 41% of global structural-parts market value, underpinned by MIIT's dual-credit NEV mandate applying to all passenger vehicle manufacturers above 30,000 annual units. The 2024 extension of NEV purchase tax exemptions through 2025 sustains near-term demand; the progressive reduction of exemption rates in 2026–2027 represents the principal watch point for deceleration risk in the region. By contrast, Europe's structural-battery supply remains exposed: Northvolt's insolvency proceedings in late 2024 confirmed that no Western-domiciled tier-1 supplier currently offers validated CTP housing at gigawatt-hour scale.
"The architectural consolidation story is frequently misread as a volume headwind for structural-parts suppliers. Our analysis shows the opposite: value migrates up the part hierarchy, and the suppliers who can meet the load-path and thermal-interface requirements of CTP and CTC programs at scale are positioned to capture meaningfully higher content-per-vehicle. The more pressing risk is a sustained BEV demand plateau in the USD 25,000–40,000 segment, not the architecture shift itself." — Aditi Rao, Claritas Intelligence
The BEV segment accounts for an estimated 61% of structural-parts demand by unit value in 2025, as skateboard platforms and gigacasting consolidate part counts and displace ICE-era casing architectures. Key companies covered in the report include Tesla, CATL, LG Energy Solution, Panasonic Holdings, BYD, Samsung SDI, SK On, Northvolt (in restructuring), Gestamp Automocion, Minth Group (formerly Shiloh Industries structural division), Nemak, and Novelis.
About Claritas Intelligence: Claritas Intelligence is a market intelligence publisher specialising in technology, automotive, and energy transition sectors, delivering quantitative forecasts and strategic analysis to investors, OEMs, and supply-chain decision-makers worldwide. Full report details and licensing options are available at claritasintelligence.com.
The full analysis, including segmentation, regional breakdowns, forecasts, and company profiles, is available in the ev Lithium Battery Structural Parts Market Report.
“The global EV lithium battery structural parts market is estimated at USD 11.8B in 2025 and the report projects growth to USD 27.6B by 2033 at an 11.2% CAGR, driven by CTP/CTC architecture adoption and sweeping EV mandates.”
Aditi Rao
Manager – Automotive