The weight reduction in transport is one of the most relevant measure to reach the legislation emissions targets legislation set to mitigate climate changes. A current challenge is to succeed in introducing the lightweighting also in fields where structural and costs restraints have limited its diffusion up to now, such as safety relevant components for commercial vehicles. The design of these new parts implies an accurate evaluation of the structural resistance, usually supported by Finite Element Analysis (FEA), laboratory analysis and testing of the operating conditions. This research reports the development of an aluminium cross beam suspension for commercial vehicles that would replace the currently used steel component. A 50% weight reduction was achieved and the geometry was firstly verified by means of FEA. Then, prototypes of the innovation were deeply characterized through microstructures, hardness tests, tensile tests, fractography, salt spray test and fatigue test bench road simulator with field test data. The validation was successfully completed and the data coming from the test benches were numerically elaborated in order to compare them with the analytical results. A specific correlation method was used. Finally, this model was proven to be reliable and it could be extended to future similar applications.