This project develops a novel hybrid manufacturing approach for lightweight automotive control arms by locally reinforcing fatigue-critical zones using Direct Energy Deposition (DED). Instead of uniform thick sheet designs, material is selectively added only where structurally required, enabling at least 20% weight reduction and 25% material savings without increasing part cost. The project integrates DED on complex formed geometries through adaptive torch kinematics and fatigue-optimized process parameters. A full-scale industrial demonstrator will be designed, manufactured, and validated at component and vehicle level. The consortium combines OEM, Tier-1, technology provider, and academic expertise to ensure direct industrial exploitation. The results transform DED from a repair technology into a design-enabled reinforcement method for sustainable, cost-neutral lightweight structures.