The process described in this paper led to the development of a novel, lightweight prototype aluminium (Al) alloy wheel carrier which substantially improves brake cooling. When compared to the standard, SG (spheroidal graphite) cast iron design, the newly developed prototype carrier has only half the mass, achieving a reduction of 11 kg per 'wheel end'. Heat dissipation from the brake disc is also considerably improved - the average convective heat transfer coefficient is increased by approximately 50 % for vehicle speeds between 30 km/h and 90 km/h. Reduced (unsprung) mass increases vehicle payload and improves dynamic characteristics, while better disc cooling reduces brake temperatures, resulting in lower disc and pad wear. Initial vehicle costs would be somewhat increased, but the operating costs, fuel consumption, CO₂ emissions and environmental impact will be reduced. Increased payload increases both vehicle and road capacity. This Al alloy carrier prototype is a valuable proof of concept, showing that good air flow (air inlet supply) and acceptable stress levels can be achieved. Further flow, thermal and structural analyses and testing will be required to fully optimise the design. Research into the most cost-effective aluminium alloys and manufacturing processes are also important steps to be undertaken in the component development process. Mass production of Al alloy wheel carriers may be still some time away for various reasons, but experience shows that despite an early reluctance to accept aluminium alloy wheels, they are now widely used in many commercial vehicle types, designs and applications. Furthermore, during the course of this project, SG cast iron 'ventilated' type carriers have entered production and are finding applications, at the moment, in commercial vehicle trailers. This is seen as a very important sign, demonstrating the wider industry (manufacturers, operators etc.) awareness of the advantages of ventilated carriers and acceptance of new technologies.