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®
Passenger Car
Chassis
Bionic Steering Knuckle
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
Powertrain
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
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
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
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
Body / Structure
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
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
