The Ultralight Steel Auto Suspensions (ULSAS) Program was undertaken by the global steel industry to demonstrate the effective use of steel in producing lightweight, structurally sound steel automotive suspensions that are manufacturable and affordable. Through the intelligent application of steel and the use of near-reach materials and technologies, the five ULSAS suspension design concepts achieves significant mass savings at no cost penalty. ULSAS achieves:

• Achieve mass savings of up to 34% over current steel design at no additional cost
• Match the mass of aluminum system, while achieving 30% cost benefit
• Does not compromise performance
• Is manufacturable in high volume at no cost penalty

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Frank Field, Randolph Kirchain, and Richard Roth, Massachusetts Institute of Technology, reprinted here by permission of the Journal of Manufacturing, summarizes the conceptual limitations in understanding cost that need to be overcome

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