Passenger Cars

We Implement Lightweight Design in Cars

Our product range covers all requirements for cast components in the car: from knuckles and wheel carriers through guides for the front and rear axles. We develop and produce engine blocks and gearbox housings as well as exhaust manifolds and turbochargers, doors made of aluminum high-pressure die- casting, or instrument cross beams made of magnesium high-pressure die-casting. We make your cars lighter.

passenger car

Body & Structure


Rear Door Frame

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                            Weight

Characteristics

Daimler

C-Klasse T-Model

AlSi10Mg

Aluminum high-pressure die-casting

Casting, punching, heat treatment, laser cutting, assembling, flattening

5.4 kg

One of the largest die-castings body & structure parts, High-precision laser-cutting

spring bracket

Front Door

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                                                                                                                                                    Weight

Characteristics

Porsche

Porsche Panamera

AlMg5Si2Mn / MgAl5Mn

Aluminum/magnesium high-pressure die-casting

Casting, machining, grinding, laser cutting, spot welding, coating, assembling

3.9 / 1.7 kg 

First aluminum structure component using the spot welding process Delta Spot as joining technology, Integration of class A surfaces 

Door Panamera

Tank Frame

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                    Weight

Characteristics

Magna

BMW 7er PHEV

AlSi10MgMn

Aluminum high-pressure die-casting

Casting, punching, heat treatment, grinding, machining, e-coating

4.0 kg

High demands on size accuracy as well as mechanical characteristics, Value chain including machining and e-coating covered by GF Casting Solutions
 

Tankrahmen1

Tank Cap

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                                     Weight

Characteristics

Magna

BMW 7er PHEV

AlSi10MgMn

Aluminum high-pressure die-casting

Casting, punching, heat treatment, grinding, machining

6.4 kg

High demands on size accuracy as well as mechanical characteristics, Wohole value chain including machining covered by GF Casting Solutions
 

Tankdeckel1

Seat Frame

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                   Weight

Characteristics

Lear

Mercedes Benz SLK

MgAl5Mn

Magnesium high-pressure die-casting

Casting, punching, shot blasting, deburring

2.0 kg

One piece design with high functional integration

Sitzlehne_Seat_Frame_SLK

Shock Tower

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                                                                                                                                                     Weight

Characteristics

Audi

Audi A6, A7

AlSi10MnMg

Aluminum high-pressure die-casting

Casting, punching, heat treatment, grinding, machining, assembling

4.3 kg

By editing the connection points lowest tolerances possible, Integration of connecting points for cables and assemblies  

spring bracket

Cross Car Beam

Customer

Vehicle

                                                                                                 Material

Process

                                                                                                              Value Chain

Weight

Characteristics

Jaguar, Land Rover

Range Rover/Range Rover Sport/Discovery

AM60

Magnesium high-pressure die-casting

Casting, machining

6.0 kg

A lot of casted features, Machining content is reduced to minimum

spring bracket

Front End Carrier

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

Weight

Characteristics

Jaguar Land Rover

Range Rover L405

AM60

Magnesium high-pressure die-casting

Finished part

5.9 kg

Component length over 170 cm

spring bracket

Front Center Console

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

Weight

Characteristics

Audi

Audi A8 (PL65)

MgAl5Mn (AM50)

Magnesium high-pressure die-casting

Casting, punching

2.48 kg 

No machining, only punched, 3 sliders, Integration of all fixing points (snap nuts), High stiffness, Strong development support by GF Casting Solutions, Integrated connection to rear center console

 

spring bracket

Rear Center Console

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

Weight

Characteristics

Audi

Audi A8 (PL65)

MgAl5Mn (AM50)

Magnesium high-pressure die-casting

Casting, punching

2.14 kg

No machining, only punched, 2 sliders, Integration of all fixing points (snap nuts), High stiffness, Strong development support by GF Casting Solutions, Integrated connection to front center console

spring bracket

Shock Tower

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                                                                                                                                                Weight

Characteristics

BMW

7er/5er GT

AlSi10MnMg

Aluminum high-pressure die-casting

Casting, punching, heat treatment, machining, laser-cutting, e-coating

4.5 kg

High functional integration, Lightweight design in aluminum HPDC for passenger cars in the luxury class

spring bracket

Door Sill Frame Member

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                   Weight

Characteristics

Audi

Audi A8

AlSi10MnMg

Aluminum high-pressure die-casting

Casting, punching, machining, assembling

10.4 kg

Structure component made by a big die-casting machine with a high degree of vertical integration

spring bracket

Powertrain


Battery Housing

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                                                                                                                                                                                                        Weight

Characteristics

BMW

BMW X5 xDrive40e

AlSi10MnMg

Aluminum high-pressure die-casting

Casting, punching, grinding, assembling, checking density, washing

9.2 kg

Finished cast component without machining  

Batteriewanne

Transmission Housing

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                   Weight

Characteristics

ZF

Volkswagen Amarok

AlSi9Cu3

Aluminum high-pressure die-casting

Casting, punching, shot blasting, machining

15.2 kg

Cast in 3D-bended steel tubes, Complex machining
 

8-Speed Transmission Housing

Engine Block

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

Weight

Characteristics

PSA

Diverse

AlSi9Cu3

Aluminum high-pressure die-casting

Casting, pre-machining

20.5 kg

Open-deck design, Integrated water-pump housing
 

Motorblock PSA 4 Zylinder

  

Engine Block

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

Weight

Characteristics

JAC

A0

MgAl5Mn

Aluminum high-pressure die-casting

Casting, machining

16.4 kg

Complex casting process, Downsizing
 

Engine Block

Turbocharger Housing

Customer

Vehicle

Material

Process

Value Chain

Weight

Characteristics

BorgWarner

BMW Engines 740 D

SiMo 1000

Iron sandcasting

Casting

4.1 kg

Weight reduction per kg including cost reduction
 

turbocharger housing

Oil Conduit Module

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                   Weight

Characteristics

Porsche

Panamera

MgAl4REMn

Magnesium high-pressure die-casting

Casting, machining, assembling

4.6 kg

Component for engines in lightweight design, First Oil Module with creep resistant magnesium alloy
 

spring bracket

Front Cover

Customer

Vehicle

Material

Process

                                                                                                              Value Chain

                                                                                                                   Weight

Characteristics

Porsche

Diverse

MgAl4REMn

Magnesium high-pressure die-casting

Casting, punching, machining, assembling

2.14 kg

Front cover with creep resistant magnesium alloy, Weight-reduced component for engines in lightweight design
 

timing chain cover

Chassis


Bionic Steering Knuckle

Customer

Vehicle

Material

Process

Value Chain

Weight

Characteristics

Study

Study

SiBoDur 700

Iron sandcasting

Raw part

3.4 kg

Weight reduction, Bionic design
 

Wheel Carrier

Wheel Carrier

Customer

Vehicle

Material

Process

Value Chain

Weight

Characteristics

Volkswagen

Diverse

SiBoDur 700

Iron sandcasting

Raw part

4.9 kg

High cost reduction due to optimization of the process and material
 

Wheel Carrier

Products & Solutions