Wrought alloy aluminium such as AA 6082 is traditionally based on virgin aluminium and some small amount of recycled internal scrap. The “sink” of recycled aluminium is mostly cast alloys. The papers describes how changes to the material tolerances, reverse logistics and novel sustainable business models are key elements for a sustainable use of post-consumer scrap in high-end structural components based on wrought alloy aluminium. The paper describes the results from the EU FP7 Project “SuPLight” and demonstrates why a holistic view and a cross- disciplinary approach are needed. A generic framework for simulation-based optimization is described as well as novel aluminium technology preparing for post consumer scrap recycling of aluminium to high-end wrought alloys. An alternative manufacturing process route for wrought aluminium forging directly on casted billets, omitting the extrusion process step, has been developed.