We present the development process of a thin wall exhaust system. The Lightweight Exhaust System allows a weight reduction ranging from 30% to 50% with increased functionality (Ref. 1), as compared with more conventional designs. The weight savings are achieved essentially by reducing the material gauges. This is made possible by the use of optimized fixing points of the exhaust system under the vehicle and the use of decoupling elements to reduce the effect of high and low frequency engine movements.