Global EV Closure Trends: A Benchmarking Deep Dive into Premium Door, Hood, and Tailgate Designs

By Akli Mesroua – October 7, 2025

As electric vehicles (EVs) continue to redefine automotive design, closures—doors, hoods, and tailgates—are no longer just a functional components. They have evolved into critical interfaces that shape user experience, styling, manufacturing efficiency, and safety. A2MAC1’s latest benchmarking study explores closure systems across five globally significant EVs, each representing distinct regional strategies.

Diverse Closure Strategies Across Régions

The study compares the Xpeng G9, Xiaomi SU7, Volkswagen ID.4, Lucid Air, and Mahindra XUV400, highlighting how closures reflect regional priorities:

• Xpeng G9 (China): Aerodynamic aluminum closures with flush handles enhance range and aesthetics.
• Xiaomi SU7 (China): Tech-inspired minimalism with smart access and cost-effective execution.
• Volkswagen ID.4 (Germany): Steel-based closures focused on durability and NVH performance.
• Lucid Air (USA): Luxury closures with powered operation, soft-close doors, and mixed-material construction.
• Mahindra XUV400 (India): Robust, cost-optimized steel closures tailored for urban EVs.

Door Frame Benchmarking: Frameless vs. Framed

A2MAC1’s analysis reveals a clear divide in door frame strategies:

Vehicle: Door Frame / Type Material / Weight (kg) / Dimensions (mm)

XPENG G9: Frameless / Aluminium / 12.83 / 12010 x 996 x 174
Xiaomi SU7: Frameless / Steel / 16.24 / 1196 x 763 x 175
VW ID.4: Framed / Steel / 20.33 / 1241 x 1257 x 256
Lucid Air: Framed / Aluminium / 12.30 / 1200 x 1080 x 204
Mahindra XUV400: Framed / Steel / 17.45 / 1195 x 1120 x 190

Frameless doors offer sleek styling but pose challenges in NVH and water management. Aluminum frames reduce weight by up to 60% but increase costs by 50–60%.

Door BIW Complexity and Weight Trends

The study also compares front door BIW weight vs. part count across 25 vehicles. Notably:

• Cadillac Lyriq has the heaviest BIW due to thicker panels.
• Toyota Crown and Prius show higher part complexity due to additional brackets.
• Tesla Model S and Model Y stand out for lightweight designs.

Xiaomi SU7: Detailed BIW Analysis

The Xiaomi SU7’s front and rear door BIW structures reveal strategic use of reinforcements and brackets to optimize stiffness as well as safety. The rear door latch reinforcement is notably larger, enhancing structural integrity.

UTS Distribution: Material Strength Mapping

Weight distribution and ultimate tensile strength (UTS) mapping for Xiaomi SU7’s door frames show:

• High-strength zones in intrusion beams and outer panels.
• Strategic use of lower-strength materials in brackets and guides.

Hood Frame Innovations

Lucid Air and Xiaomi SU7 feature adjustable striker plates for precise hood alignment. Lucid’s hood striker allows ±2.75mm in X and ±1.52mm in Y adjustments.

Tailgate Trends: Material and Mechanism Choices

Tailgate designs vary significantly:

Vehicle: Type / Material / Weight (kg) / Dimensions (mm)

XPENG G9: Tailgate / Aluminium / 12.47 / 1400 x 900 x 600
Xiaomi SU7: Trunk Lid / Steel / 12.12 / 1310 x 610 x 540
VW ID.4: Tailgate / Steel / 26.10 / 1288 x 960 x 612
Lucid Air: Trunk Lid / Plastic / 15.71 / 1785 x 510 x 690
Mahindra XUV400: Tailgate / Steel / 12.84 / 1380 x 1115 x 300

Premium vehicles increasingly adopt plastic tailgates for styling and weight reduction, despite higher costs and supplier challenges.

Hood Latch System Trends

Two major trends are reshaping hood latch systems:

• Trend 1: Dual-stop latches eliminate the need for manual secondary release.
• Trend 2: Electric actuators enable remote unlocking, enhancing convenience and safety.

Profiling Type Hinge

Profiling hinge type is preferred in premium EVs (Xiaomi, XPENG, Audi, VW) for precision, durability, and perceived quality, though it comes with higher manufacturing cost.

• Complex Manufacturing: Requires multiple processing stages, including post-processing and machining, unlike stamping.
• Higher Material Usage: Consumes more raw material, leading to increased production cost.
• Heavier Design: Results in higher component weight compared to stamped hinges.
• Cost Implications: Additional machining and material usage increase overall manufacturing expense.
• Suitability: Better suited for heavy-duty applications where strength is prioritized overweight and cost.

A Global Shift in Closure Design

This benchmarking study underscores how closures are becoming strategic differentiators in EV design. From material choices to latch mechanisms, OEMs are innovating to balance cost, performance, and user experience.
A2MAC1 provides deep insights into these evolving trends, helping stakeholders navigate the future of automotive engineering!