Turn twenty pieces into one
GF Casting Solutions plans to produce a single cast aluminum part to replace multiple sheet metal pieces to make car bodies, aiming to simplify production. Co-developer Stephan Philipp presents the component.
Pioneering work
GF Casting Solutions leads in large automotive structural components by integrating multiple functions and reducing assembly parts.
The challenge
Stephan Philipp
Position: Team Lead Product Development
Division: GF Casting Solutions
Location: Schaffhausen (Switzerland)
Joined GF in: 1994-1997, 2005
The front partition wall between the interior and the engine compartment previously consisted of several individual components. A large, one-piece casting solution replacing individual components could streamline production processes. But integrating it into the assembly sequence is challenging and does not allow for tolerance compensation like individual components.
The process
My colleague Fabian Kohlbrenner and I analyzed car bodies from various manufacturers to identify areas that could accommodate and benefit from a large structural part. The decisive factors were areas that are geometrically complex and structurally relevant. This is where casting can realize its full potential. We then drafted concept designs and calculated initial stiffness, strength and crash simulations using 3D data from our design software.
The result
Fabian Kohlbrenner
Position: Development Engineer Product Development
Division: GF Casting Solutions
Location: Schaffhausen (Switzerland)
Joined GF in: 2018
The new component, designed for mid-size to luxury cars, significantly reduces auto manufacturers‘ assembly workload. Previously requiring 20–30 sheet metal parts, it now consists of one large casting, eliminating steps like welding and riveting to save time and money. Depending on the manufacturer, the concept can be adapted to a specific vehicle platform used in various types of vehicles. In the future, we will be able to apply the knowledge we have gained to similar large cast components.