The weight reduction potential of Hylite sandwich sheet in applications where bending stiffness is the design criterion is approx. 65% over steel sheet and 30% over aluminum sheet. The sandwich sheet (0,2/0,8/0,2mm aluminum/polypropylene/aluminum) has proven its functionality in numerous prototype car body parts which have been tested thoroughly by car manufacturers. In order to demonstrate its suitability in today's car manufacturing environment Hoogovens Hylite in close collaboration with Volkswagen AG and Grau Werkzeug- und Formenbau GmbH has set up a prevalidation line for the production of car hoods. The emphasis in the project has been on deep drawing and an innovative hemflanging technology involving a preparatory ‘ribbing’ operation. The aim was to prove that the deep drawing and subsequent hem flanging operation can be carried out in an acceptable cycle time at high quality standards and at a low rejection rate.