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Most large automobile parts, such as door panels, are made from multi-piece, multistep steel stamping and joining processes. However, automakers must meet challenging standards and improve fuel economy through the use of lightweight materials and innovative manufacturing methods. Magnesium, the lightest structural metal available, presents the greatest opportunity for vehicle lightweighting, but is not pervasively used due to higher costs and other barriers.

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications