Cross Car Beam HUD

Winner Magnesium

Dimension (L x W x H): 508 mm x 300 mm x 1523 mm

Weight: 3.480 gram

Alloy: AM50

Highly stressed component which must also offer very high stiffness under dynamic loads in order to exclude vibrations, e.g. in the area of the steering wheel or the head-up display. In addition, the component must allow a high degree of deformability (e.g. in crash behavior).

Design, casting and molding requirements:
Representation of the necessary requirements in a restricted installation space, which meant that the cross sections in the casting had to be designed flexibly. The ribbing was designed to meet the stresses, which was continuously evaluated by simulation in terms of mold filling and solidification behavior. Integration of as many different functions as possible in the casting (attachment of add-on parts, integration of brackets, etc.).

Reasons for manufacturing in die casting:
Due to the highly restricted installation space, die casting offers the possibility of optimum utilization of the free spaces and thus a design that is more suitable for the stresses. In addition, the use of magnesium makes it possible to achieve the high stresses in a low weight.