Impact extrusion has been an important forming process for the production of rotationally symmetrical components for years. Especially its high productivity, dimensional accuracy, material and energy efficiency, makes this process interesting for Original Equipment Manufacturers (OEM) in the automotive industry. Due to the energy transition and environmental aspects, resource conservation and sustainability are becoming increasingly important and will be an additional selection criterion for OEMs in the automotive sector in the future. For this reason, a total of three prototypes were designed, simulated and tested. As a first step, several lubricants were investigated and simulatively validated by means of experimental ring compression test to tribologically optimize the process. A nomogram was created from the evaluated data, comparing the tribological properties of the lubricants and served as a decision-making support for lubricant selection. Regarding the design, the construction of the punches, dies and reinforcement rings for the process are elaborated. To verify the process capability of the design, a numerical simulation based on the Finite Element Method (FEM) was carried out, which is to be understood as a feasibility study for the process. This allowed various process parameters to be calculated and investigated, which consequently revealed optimization potential for the subsequent prototype. In the subsequent tests, the prototypes were examined for their process capability and, if necessary, the damage mechanisms were evaluated for further prototype development. As a result of this work, a new impact extrusion process for expanding the product portfolio of an aluminium roll-off piston for passenger car air suspension systems was developed and implemented in a small to medium-sized enterprise (SME). The associated process portfolio expansion is intended to qualify the company as a supplier for larger impact extrusion components in the future.