Röchling Automotive: Metal-Plastic Hybrid Technology Cuts Cockpit Cross Beam Weight by Up to 37%

Cockpit cross beam - (Photo: Röchling Automotive).

Röchling Automotive is developing metal-plastic hybrid solutions for cockpit cross beams and expanding its activities in Europe, North America and Asia. The company says it has secured several production and development projects in these regions in recent years. The components are part of the automotive supplier's structural lightweighting business.

Cockpit cross beams, also known as cross car beams, provide structural support behind the dashboard. They must meet stringent stability and safety requirements while serving as mounting points for various cockpit components. Traditionally, these structures have been made primarily from steel or aluminium. By combining metal and plastic, manufacturers aim to reduce weight while integrating additional functions directly into the component.

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Internal Calculations Show Potential Material Savings
According to an internal design study, a hybrid cockpit cross beam can weigh up to 37% less than a comparable aluminium design. Material-related greenhouse gas emissions could also be reduced by up to 66%. The figures are based on technically comparable component designs, taking into account their bills of materials, material compositions and weights. The calculations assume the use of primary aluminium for the conventional design.

The emissions comparison covers only the global warming potential of the materials used, expressed in CO₂ equivalents. It excludes emissions from manufacturing and transportation and therefore does not represent a full life cycle assessment. As a result, the stated reductions should not be interpreted as savings in the overall carbon footprint of the finished component.

Expanding Development and Production Worldwide
Röchling Automotive says it is bringing together its development and manufacturing operations to support hybrid solutions throughout the entire process, from design and simulation to industrialisation and high-volume production. The company aims to strengthen its structural lightweighting business by expanding these projects.

The announcement does not disclose customer names, planned production volumes, specific production start dates or potential cost savings.

The Röchling Group reported revenue of €2.6 billion in 2025. According to the company, it employed 11,401 people across 84 locations in 25 countries.

More information: www.roechling.com

Röchling Automotive SE, Worms, Germany

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