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Member Spotlight: GF Casting Solutions AG
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Name of Part: Cross Car Beam
Product Using Part: Jaguar Land Rover Defender Cockpit
Function: Bracket parts with visible A surface in the instrumental panel
Alloy Used: AM60


Visible Magnesium Surface:
GF Finishers Refining Jaguar Land Rover’s (JLR) New Defender Cockpit

On the market since spring 2020, the modern and technical interior design of the JLR Defender showcases casting innovation and great success in the field of Magnesium structural parts.

Defender: Comeback of an icon
In 2019, almost three years after the production stop of the traditional JLR Defender - known from the US TV series Daktari - GF Casting Solutions AG received the honor of developing components for the new version of the off-road legend. Thanks to strong teamwork and many years of know-how, five lightweight Magnesium components were created which, together with the cross car beam, form the basis of the instrument panel. Thanks to the preservation of the angular basic shape and a new, contemporary design, both die-hard fans as well as new customers can enjoy the traditional vehicle.

Bracket parts with visible A surface in the instrument panel
Providing off-road look and clear geometries, the new cockpit with a high percentage of Magnesium surfaces is a role model for the usage of structural parts in Magnesium high-pressure die casting. With the set of five lightweight Magnesium parts in addition to the Magnesium Cross Car Beam, GF Casting Solutions has created a complete structural solution which is not only light and stable, but noble. All the visible Magnesium parts show A surface quality in the instrument panel – the cover plate at the passenger side even features the Defender lettering integrated into the casting.

The very high surface quality requirements can only be met through long-standing experience in Magnesium casting and very reliable manufacturing processes. Altogether, the five components are building the base for the instrument console. Before the set of Magnesium components leaves its home base at GF Casting Solutions Altenmarkt in Austria, they are coated and assembled.

Cross Car Beam: Heart of the cockpit’s structure
In comparison to conventional solutions, the one-piece cast Cross Car Beam – which belongs to the crash-relevant parts in the cockpit – replaces up to 10 individual components. Further components inside the cockpit such as head-up display, air conditioning, ventilation channels, knee air bag, glove compartment and steering console are attached to the cross car beam and its Magnesium finishers. For the final assembly, the 1.50 meter component is simply screwed to a few attachment points like for example the A pillar and the center console.

Extended casting competence: High-quality and complex tooling
The manufacturing process of the five bracket parts requires complex and up to 2-cavity die-casting tools and high-class trimming competence to guarantee the high quality of the component’s surface. The A surface area in the tool is therefore surface treated. After the casting process, the Magnesium high-pressure die casting parts are powder coated with very small tolerances and very high requirements. Besides, the Magnesium offers high functional integration and meets all requirements of safety at an extremely low weight.


Cross Car Beam
Cross Car Beam. Photo courtesy of GF Casting Solutions.
Center stack
Center stack. Photo courtesy of GF Casting Solutions.


end caps
Right and left end caps. Photo courtesy of GF Casting Solutions.


Diver's side finisher. Photo courtesy of GF Casting Solutions.


cover plate
Passenger side cover plate features the Defender lettering. Photo courtesy of GF Casting Solutions.

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