A new Blow-Molded Roll-Bond (BMRB) aluminum technology has been developed to produce a durable, light-weight, double-wall heat shield with high performance characteristics. The resulting heat shield product is known as an Airgap heat shield. Theoretical results indicate that radiation heat shields should be made from materials with low emissivity and designed to maintain low emissivity levels. Wind tunnel testing showed that Airgap heat shields provide adequate thermal protection and road test results verified the thermal performance and durability of these heat shields. This heat shield technology is currently being used for volume production on a minivan platform.