The aim of this project is to develop magnesium alloys extrusion technology for large profiles for application in the automotive industry. In particular it is expected to significantly reduce chassis weight, thus leading to fuel consumption reduction and enhancement of performance of the cars produced by the end user. The entire process required for magnesium alloys extrusion of automobile chassis will be addressed as a first attempt of large magnesium profile extrusion. The challenge of large magnesium profile extrusion (outer diameter up to 10") has never been addressed due to technological barriers that relate to limited capability of magnesium extrusion technology. However, these barriers can be overcome if one has control over the starting material. Since the final performance of the finished product depends on the original microstructure formed over Direct Chill (DC) casting, homogenization, extrusion and subsequent heat treatment, no processing step can be isolated from the other. The R&D activities will focus on alloy selection, production of large magnesium billets, die design, heat treatment and extrusion parameters. These will be accompanied by an economic assessment of the new technology and additional applications.