Light weighting of vehicle doors is a challenge faced by all vehicle manufacturers - whether passenger cars and vans or large commercial vehicles like trucks and buses. This need is driven not only by the desire to improve the vehicle's fuel economy, but also by the implication of the doors on the buyer's perception of the vehicle's quality.The best solutions to these needs emerge from an unbiased consideration of different materials and product forms in the design and development of lightweight doors. To demonstrate this notion, a truck door was designed that has the potential of providing both improved fit as well as enhanced structural performance. The concept also simplifies the manufacturing process thereby minimizing system cost while offering approximately 7% additional weight saving compared the door already made from light weight materials (aluminum). This paper describes the design concept for lightweight vehicle doors using aluminum in its various product forms as well as other materials.