This paper explores the principles of lightweight design using aluminium as the material of choice, highlighting its advantages and key design considerations. Aluminium's low density, high strength-to-weight ratio, and excellent corrosion resistance make it ideal for weight reduction in various applications and industries. The paper discusses the importance of holistic design approaches, the challenge to define the matching material, identify interactions between material and processing routes and how reliable decisions especially during the early phases of the development process can be made when time is limited and constraints.

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