New trends in the design of automotive components have been focused on the production of thin-wall cast iron castings to save materials and energy. Recently, there has been an increase in demand for thin wall iron castings (TWCI) with a wall thickness below 3 mm and with a high strength-to-weight ratio. The development of thin wall technology will permit the automakers to make a better-informed choice between competing materials and thin wall cast iron with its different types ( DI, ADI, SiMo DI and Vermicular graphite iron), thus decreasing the overall cost of the automobile. The effect of various parameters to produce sound and free carbides ductile iron castings was discussed. The parameters included molding materials, chemical composition, pouring temperature, types of inoculants and its amount as well as austempering treatment parameters for ADI and other foundry basic practices. New trends and developments of thin wall castings for four grades of iron casting have been reported. The four grades are: ductile iron for primary pump bodies, ADI for gears and hollow connecting rods, heat resistant SiMo for exhaust manifolds and finally, vermicular graphite iron for heads and brake systems. Some of successful applications for the four grades of thin wall cast iron especially in the automotive applications are reported. Recent research work at CMRDI has revealed that thin wall cast iron plates (3mm thick) made of DI, ADI and SiMo DI can be produced without carbide formation by controlling the parameters mentioned above.