Energy bandwidth studies can serve as foundational references in framing the range (or bandwidth) of potential energy savings opportunities in U.S. manufacturing. This bandwidth study is one of a series of six energy bandwidth studies on lightweight structural materials manufacturing. The study examines energy consumption and potential energy savings opportunities in U.S. aluminum manufacturing. The study relies on multiple sources to estimate the energy used in the manufacturing of the material for lightweighting applications (automotive and aerospace), accounting for approximately 28% of overall U.S. aluminum production in 2010. Energy savings opportunities for the five manufacturing subareas studied are based on technologies currently in use or under development.