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
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.