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Marelli's LeanExhaust Wins Prestigious Award

Marelli, a prominent player in the automotive technology arena, recently clinched the coveted Innovations in Lightweighting Award from the Society of Automotive Analysts (SAA). This recognition, awarded on November 13, 2025, during the 9th Annual Materials Innovation Summit in Auburn Hills, Michigan, underscores Marelli's commitment to sustainability and technological advancement in the automotive sector.

The LeanExhaust Breakthrough

The award-winning LeanExhaust system represents a game-changing innovation aimed at addressing the automotive industry's need for lighter, more efficient, and environmentally friendly vehicle components. Traditional exhaust systems often contribute significantly to a vehicle's overall weight and carbon footprint. Marelli's LeanExhaust system not only lightens the load but also enhances overall performance with significant environmental benefits.

A 16 kg Weight Reduction

Key to LeanExhaust's success is its lightweight design, which achieves a weight reduction of 16 kg compared to conventional exhaust systems. This reduction plays a pivotal role in improving fuel efficiency and lowering emissions, aligning with global automotive goals to enhance sustainability. Notably, the LeanExhaust system supports a 52% reduction in carbon emissions, translating to approximately 85 kg less CO2 for each vehicle. This innovative solution addresses the growing demand for hybrids and vehicles with internal combustion engines, marking a significant leap in design efficiency.

Cutting-Edge Component Design

The system's design features two critical components that contribute to its performance and efficiency:
1. Dual-layer converter: This unique component integrates a three-way catalytic converter with a gas particulate filter, resulting in a 45% reduction in weight and a 46% decrease in volume. This advanced structure ensures the catalyst reaches its ideal operating temperature swiftly, which is essential during a vehicle's cold start and while driving in electric mode.
2. Micro-hole design muffler: This innovative muffler utilizes a micro-perforated central tube with baffles, eliminating the need for non-recyclable materials such as glass wool found in traditional mufflers. The design allows for a 27% weight reduction and a 15% decrease in volume, all while maintaining effective noise reduction and enabling the use of thinner, more durable stainless steel in construction.

Environmental Impact and Recyclability

Beyond the immediate weight savings, Marelli's LeanExhaust system promotes enhanced recyclability, aligning with the increasingly important demand for sustainable automotive solutions. The system not only meets but exceeds current standards for emissions and noise control without compromising durability. Marelli's Green Technologies division chief, Shuji Kobayashi, emphasized that this achievement represents the team’s relentless pursuit of sustainable mobility, establishing a new benchmark in exhaust system design and manufacturing.

Acknowledgment of Further Innovations

Marelli's achievement at the SAA Awards also included an Honorable Mention for its hybrid suspension system with electromechanical actuators, showcasing the company's wide-ranging innovations in automotive technology. This fully active system allows improved control of vehicle dynamics while achieving a 57% weight saving compared to conventional hydraulic systems.

About Marelli

Marelli is a global mobility technology supplier with a mission to transform the future of mobility through innovation and collaboration. With a diverse workforce of around 40,000 employees across 150 sites worldwide, Marelli is firmly positioned to lead the charge towards a safer, greener, and better-connected world.

Conclusion

The LeanExhaust platform by Marelli demonstrates not only technological innovation but also the company's commitment to improving sustainability within the automotive industry. As regulations become stricter and consumer preferences shift, such advancements will play a crucial role in shaping the future of vehicle design and production.