Engineers have developed an ultra-light composite called TCA Float, designed specifically for the Corvette — combining exceptional strength with reduced mass.
A breakthrough material from Continental Structural Plastics (CSP) could change the way performance cars are built. The company — which supplies body panels for the Chevrolet Corvette — has unveiled a new composite called TCA Float, offering a remarkable 23% weight reduction without sacrificing strength or surface quality.
According to CSP, TCA Float has a record-low density of under 1.0 g/cm³, making it the lightest paintable composite available for exterior automotive panels. Despite its featherweight nature, it maintains the same durability, rigidity, and finish quality as previous-generation materials.
Even better, automakers can integrate TCA Float into existing production lines without any tooling or process changes — a key factor for large-scale manufacturing.
By using this new composite, CSP estimates that a vehicle’s body weight can be reduced by around 24 kilograms (53 pounds). For a sports car like the Corvette, where every ounce affects handling and acceleration, that’s a meaningful improvement.
The company says the material’s name — TCA Float — comes from its ability to literally float on water. This unique property symbolizes its extreme lightness and efficiency. CSP believes that with TCA Float, future sports cars, including upcoming 2026 models, will achieve even better aerodynamics and fuel efficiency while maintaining the high-quality surface finish and reliability expected from premium performance vehicles.