The Honda Insight features lightweight plastic panels which are used extensively in non-structural applications. The front fenders, spoilers, under body cover and rear fender skirts are all made of plastic. Also, lightweight sound insulating materials are used throughout the Insight.

The bumper beams, steering hanger, roof, floor, front and rear wheel wells, rear quarter-panels, bulkhead, and even doors and hood, are made of aluminum alloy. These stressed panels are reinforced in key areas by the aluminum-alloy frame members.