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

Chassis


Bionic Steering Knuckle

Customer: Study

Vehicle: Study

Material: SiboDur 700

Process: Iron sand casting

Value chain: Raw part

Weight: 3.4 kg

Characteristics:

  • Weight reduction 22%
  • Bionic design development with high strength casting material SiboDur®
Wheel Carrier

Wheel Carrier

Customer: Volkswagen

Vehicle: Golf platform

Material: SiboDur 700

Process: Iron sand casting

Value chain: Raw part

Weight: 4.9 kg

Characteristics:

  • High cost reduction due to optimization of the process and material
Wheel Carrier

Damper Fork

Customer: Audi

Vehicle: AUDI A4/A5/A7/A8/Q5

Material: SiboDur 700-10

Process: Iron sand casting

Value chain: Casting, machining, coating

Weight: 1.7 kg

Characteristics:

  • Functional integration
Wheel Carrier

Powertrain


Oil Conduit Module

Customer: Porsche

Vehicle: Panamera

Material: MgAl4REMn

Process: Magnesium high-pressure die-casting

Value Chain: Casting, machining, assembling

Weight: 4.6 kg

Charakteristics:

  • Component for engines in lightweight design
  • First Oil Module with creep resistant magnesium alloy
  • IMA Award 2014 “Casting Design Automotive”
spring bracket

Battery Housing

Customer: BMW

Vehicle: X5xDrive40e

Material: AlSi10MnMg

Process: Aluminum high-pressure die-casting

Value chain: Finished part

Weight: 6.4 kg

Characteristics:

  • Installation into vehicle without machining  
Batteriewanne

8-Speed Transmission Housing

Customer: ZF

Vehicle: Miscellaneous

Material: AlSi9Cu3

Process: Aluminium high pressure die-casting

Value chain: Pre-finished

Weight: 12.1 kg

Characteristics:

  • Cast-in 3D-bended steel tubes
  • Finished cast gear rim
  • Process integrated dynamic pressure and roundness testing
8-Speed Transmission Housing

8-shift-gearbox-housing for double-clutch-transmission

Customer: ZF

Vehicle: Porsche Panamera

Material: AlSi9Cu3

Process: Aluminium high pressure die-casting

Value chain: Raw casting

Weight: 9,97 + 16,94 + 2,79 = 29,7 kg

Characteristics:

  • Finished cast gear rim
  • GF supplies the gearbox-housing, clutch-housing and gearbox-cover
  • Picture shows all three parts in assembled condition
8-Speed Transmission Housing

Front Cover

Customer: Porsche

Vehicle: Porsche Panamera / Cayenne

Material: MgAl4RE4Mn

Process: Magnesium high pressure die-casting

Value chain: Casting, punching, machining, assembling

Weight: 2.14 kg

Characteristics:

  • Front cover with creep resistant magnesium alloy
  • Weight-reduced component for engines in lightweight design
  • IMA Award 2011
timing chain cover

Turbocharger Housing

Customer: BMW

Vehicle: BMW 740 D

Material: SiMo 1000

Process: Iron sand casting

Value chain: Raw part

Weight: 2.2 kg

Characteristics:

  • Weight reduction per kg lead to cost reduction
  • Range of application to 900°C
turbocharger housing

Engine Block

Customer: PSA

Vehicle: BMW 1er, Mini

Material: AlSi9Cu3

Process: Aluminium high pressure die-casting

Value chain: Casting, pre-machining (cubing)

Weight: 20,5 kg

Characteristics:

  • Open-deck-design
  • Integrated (casted-in) grey-iron cast liners
  • Integrated timing-chain-box
  • Integrated water-pump housing
Motorblock PSA 4 Zylinder

  


Engine Block

Customer: JAC

Vehicle: AO

Material: AlSi9Cu3

Process: Aluminium high pressure die-casting

Value chain: Casting, machining

Weight: 16.4 kg

Characteristics:

  • Complex casting process
Engine Block

Body / Structure


Rear Door Frame

Customer: Daimler

Vehicle: C-Klasse T-Model

Material: AlSi10Mg

Process: Aluminium high-pressure die-casting

Value Chain: Casting, punching, heat treatment, laser cutting, assembling, flattening, polishing

Weight: 5.4 kg

Characteristics:

  • NADCA Award 2016

  • One of the largest die-castings body & structure parts

  • High-precision laser-cutting
spring bracket

Seat Frame

Customer: Lear

Vehicle: Mercedes SLK

Material: MgAl5Mn

Process: Magnesium high pressure die casting

Value Chain: Casting, punching, shot blasting, deburring

Weight: 2.05 kg

Characteristics:

  • IMA Award 2015

  • One piece design with high functional integration

  • Crash characteristics
Sitzlehne_Seat_Frame_SLK

Front Door

Customer: Porsche

Vehicle: Porsche Panamera

Material: AlMg5Si2Mn / MgAl5Mn

Process: Aluminium / magnesium high pressure die-casting

Value chain: Casting, machining, grinding, laser cutting, spot welding, coating, assembling

Weight: 3.9 / 1.7 kg

Characteristics:

  • First aluminium structure component using the spot welding process Delta Spot as joining technology
  • Integration of class A surfaces
  • First window frame on the market produced in magnesium high pressure die-casting
Door Panamera

Spring Bracket

Customer: Audi

Vehicle: Audi A6, A7

Material: AlSi10MnMg

Process: Aluminium high pressure die-casting

Value chain: Casting, punching, heat treatment, grinding, machining, assembling

Weight: 4.3 kg

Characteristics:

  • By editing the connection points lowest tolerances possible
  • By heat treatment T6 a long-term heat stability of the parameters obtained
  • Integration of connecting points for cables and assemblies
spring bracket

Products & Solutions