Porsche Panamera Rear subframe (winner)
Farsund Aluminium Casting AS / Porsche AG
Award category for entry:
Industrial > Automotive & Transport
Taken into production / produced on:
Nature of the project:
Main rear axle part, cast in vacuum assisted low pressure die casting. Safety functional chassis part mounted in each Porsche Panamera model. Interface between car body and wheel suspension. Before final axle assembly the part is machined and 4 bushings are pressed in
Light-weight car subframe for safety functional application with high requirements in strength and stiffness. Cast as one piece in hollow design using only one sand core. With a size of 1200 by 710 by 335 mm and wall thickness down to 3,5 mm it expands the dimensions of usual aluminium castings for chassis application. The concept substitutes usual multi-part solutions and allows a high degree of functional integration
Reason for entry/innovative aspects:
The true value of the Porsche Panamera rear subframe is that is has expanded the boundaries of what is possible in both casting and automotive design. As an alternative to the traditional welded steel sheet design concept, this ultra light weight hollow core aluminium casting is an all round winner.
Compared to the traditional sheet steel design the aluminium casting has slashed costs in the supply chain by consolidating 30+ parts into a single casting. This removes the need for complex production lines and all the associated tooling. The panamera subframe is very strong too, with the demands of a Gran Turismo it has to perform to extremely high requirements for driving dynamics and comfort. Its weight of 16 kg has a significantly positive impact on the environment with saving of at least 4 kg per car compared to steel.
The manufacturing process is equally unique and designed for maximim efficiency. The casting process takes just 4 minutes due to extensive chilling of mould with water channels during solidification. Even the T6 heat treatment process has a dual role allowing the part to relax into dimensional tolerance and avoiding the need for an additional straightening process step. The subframe represents a world premiere application of combined solutions not available in automotive chassis parts until now.
The one-piece concept with a high degree of functional integration also means less efforts during axle assembly as well as the reduction of investments.