Current helicopter gearbox housings are often made with magnesium (Mg)-based alloys for their high castability and low density. Replacing Mg alloys with aluminum (Al) alloys would improve corrosion resistance and galvanic degradation. However, current Al casting alloys lack the castability to produce complex housing geometries cost-effectively and as lightweight as competing Mg alloys. Furthermore, current high strength Al alloys cannot be processed via Additive Manufacturing (AM)—they crack during the AM process. A new high-strength Al alloy processed via AM can address both of these issues and enable longer service life in gearbox housings. QuesTek Innovations is using its Integrated Computational Materials Engineering (ICME) technology to develop high strength Al alloys suitable for AM. QuesTek has developed a hot-tear cracking index to predict which alloys will crack upon cooling and used this index to design three high-performance hot-tearing-resistant Al alloys. QuesTek is working with partners to evaluate component-level demonstrations of these alloys.