Lightweight HPDC Subframe for Volume Cars

The development of vehicle components requires an optimal balance of cost, weight, and performance. Nemak addresses this challenge with a one-piece aluminum HPDC subframe (see image) that combines lightweight design and cost efficiency for high-volume vehicle applications. To demonstrate technical feasibility, a rear subframe was developed to meet stiffness, strength, and crash requirements. The design replaces around 30 steel components, reduces weight by 25 %, and improves NVH performance. Component quality is ensured through simulation of casting processes and material properties. Advanced structural optimization enables high weight-specific performance, while locally hollow sections offer additional potential. Following successful prototype manufacturing, further development toward series production will be pursued together with customers.