Turn twenty pieces into one

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.

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 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.