AUBURN HILLS, MI—Engineers at FCA and Oak Ridge National Laboratory recently developed a new aluminum alloy that stays strong up to 572 F. The new alloy can also be cast and machined using existing technologies.

If it rolls, floats or flies, lightweighting is one of the biggest challenges facing manufacturers today. The push for new materials is forcing engineers in a variety of industries to explore cost-effective alternatives and develop new assembly processes.

For the past decade, carbon-fiber composites have been the darling of the aerospace sector, receiving countless praise and widespread attention. Reinforced polymers have dramatically changed the way that many types of airframes are designed and built.

Like a third-string quarterback awaiting his moment in the spotlight, magnesium has been sitting patiently on the light-weighting sideline. But, it may finally get its turn to shine in automotive applications, thanks to several recent breakthroughs.

As automakers and suppliers search for new ways to reduce vehicle weight, some engineers are experimenting with natural fibers. Bamboo, cotton, hemp, jute, kenaf, rice and other crops can be used to produce high-strength composite structures for automotive applications.

U.S. automakers are wrestling with the challenge of reducing vehicle weight to meet the 2025 CAFE (Corporate Average Fuel Economy) mandate, which requires new cars and trucks to achieve 55 miles per gallon. Meeting that challenge will require the latest advances in materials and fastening methods.

When it’s finished, NASA’s massive new Space Launch System (SLS) rocket will be truly awe-inspiring.

Lightweighting is the No. 1 challenge facing automotive engineers today. Manufacturers are scrambling to build vehicles that contain a variety of weight-saving materials, such as aluminum, carbon-fiber composites, high-strength steel, magnesium and plastic.