A joint project of the United States Automotive Materials Partnership LLC (USAMP) and Auto/Steel Partnership (A/SP) using structural optimization techniques and advanced high-strength steels (AHSS) within a car’s passenger compartment has shown a mass savings potential of 15-20% while remaining cost-neutral compared to use of conventional steel grades. USAMP—a subsidiary of the United States Council for Automotive Research LLC (USCAR), whose members are Chrysler Group LLC, Ford Motor Co., and General Motors Co.—and A/SP made use of computer modeling to validate the mass savings in a preproduction sedan. The Future Generation Passenger Compartment – Validation project selected AHSS for parts typically made of conventional steel for the passenger compartment of a production-viable, four-door, five-passenger sedan, and applied two new load paths (including transverse tubes that directly absorb side impact forces within the front seat). Manufacturing feasibility evaluations supported the design and use of HSS as acceptable for high-volume manufacturing. The study also evaluated the effects of continuous joining. Each OEM team member is now determining if, how, and when it will use the design process for production.