The aim of this project is to develop magnesium alloy 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 chasses 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 the 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 by DC (Direct Chill) 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. Preliminary work has shown feasibility for both design and manufacture of large scale commercial and non-commercial magnesium alloys profiles. Production has begun based on the simple ladder shape frame, which was chosen as a case study. However, in order for these to be further implemented as individual sections, composing a modern space frame, much more work in required, mainly the FEM (finite element method) simulation aspects. Extensive modelling is needed on modified sections (using both static and dynamic modules), before validation stage. As part of the long term R&D project, these stages will be addressed chronologically