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This paper examines the design challenge represented by the development of the various lightweight automotive wheel programs such as HSLA, aluminum, and plastic. A survey of the various design analysis tools available are made and the phenomenon of correlation between theoretical finite element computer analysis and experimental analysis is investigated. The design issues of optimum weight versus fatigue life, failure detection, material properties, manufacturing stresses, work hardening, temperature sensitivity, creep, and lugnut torque retention are discussed and the new experimental tools required to monitor these issues are described. This paper describes the required link between theoretical and experimental analysis, and specifically describes the creation of the sophisticated testing systems required to accomplish these analyses.