American-made goods are hot commodities these days. According to the U.S. Commerce Dept. (Washington, DC), demand for exports recently experienced its biggest monthly gain in 5 years. But, some other news is a bit more sobering.

Researchers in Europe believe the 5-day car will revolutionize automotive production. They have developed a lightweight modular car that features plastic body panels and new assembly methods.

Engineers at BMW Group (Munich, Germany) recently unveiled a shape-shifting concept car that takes the use of lightweight materials to a whole new level. Instead of using traditional metal, aluminum or plastic composites, the skin of the vehicle is made from a stretchy fabric that forms a wide variety of convex and concave surfaces.

While automakers are evaluating the use of lightweight materials, such as aluminum, composites and magnesium, they are also trying to make better use of traditional materials to lower vehicle weight. As a result, the use of sheet steel in automobiles may not decline rapidly, but be replaced using thinner grades of high-strength, low-allow steels.

Because magnesium is one-third lighter than aluminum, it is very appealing to automotive engineers. More and more automakers use using magnesium sheets and castings in front-end engine compartment applications, replacing what is currently sheet steel. However, because of the lack of elasticity in magnesium, at times traditional thread-forming screws are not functional.

Plastic is the most common lightweight material used in automobiles today. However, automakers continue to find new uses for the material, especially in under-the-hood applications.

Titanium is a strong, lightweight material that has always been too expensive for most automotive applications. But, that could soon change, thanks to a new process being developed by engineers at Oak Ridge National Laboratory.

During the 1960s and 1970s, Team Lotus (Hethel, England) was synonymous with cutting-edge racecars, innovative engineering ideas and world-champion drivers. Today, the company if developing lightweight sports cars by focusing on sustainable materials such as hemp.

Automakers and suppliers have been focusing on vehicle weight for decades. But, rising fuel prices and strict government fuel-economy mandates are forcing the industry to explore new applications for lightweight materials, such as aluminum, composites and magnesium.

If you think you work too much, maybe you better slow down. If not, you may end up like an engineer at a Japanese automaker who recently worked himself to death.