Lightweighting of automobiles has become a major goal for vehicle manufacturers, due to high fuel costs, stricter emission norms, energy security worries and recycling concerns. Heavy steel parts have to be replaced with light metal alloy parts that match the excellent material properties provided by the steel varieties. The design and fabrication of such high-strength aluminium components needs new knowledge and intensive processeswith precise process controls. The automotive industry is willing to accept only high volume production processes, with low per part costs. They are also ready to accept higher initial capital investments and sophisticated processes, when it enables fast, accurate and reliable fabrication methods.