In new vehicles development weight reduction is one of the most important driving forces often conflicting with other missions that would require additional mass (crashworthiness, comfort, etc). The use of HSS, especially new grades with very high strength and good formability is the most competitive way to reduce weight. Nevertheless some limitations come from manufacturing HSS: springback, residual stresses, weldability and should be taken into account in product development in order to avoid an expensive set up phase in the press shop and in the body shop. This paper focus on the recent experience achieved by Fiat in introducing HSS up to reach a share higher than 60 percent in weight while applying and developing new methodologies to solve in the design phase any criticality arising from the use of this material.
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