JLR Redesigns Dashboard Crosscar Beam to Cut Over 50,000 Tonnes of CO2 Emissions Annually
Jaguar Land Rover (JLR) has innovatively redesigned the crosscar beam in its future vehicles by replacing magnesium with a hybrid of fibre-reinforced plastic and steel. This change is anticipated to cut over 50,000 tonnes of CO2 emissions annually, equating to the energy consumption of approximately 17,000 UK homes. The crosscar beam, essential for safety features like airbags, has undergone extensive testing to ensure it combines lightweight properties with strength. This initiative aligns with JLR's sustainability goals under its Reimagine strategy, emphasizing reduced emissions in automotive development.
JLR Redesigns Dashboard Crosscar Beam to Cut Over 50,000 Tonnes of CO2 Emissions Annually
JLR has redesigned the crosscar beam used in its upcoming vehicles, replacing magnesium with a hybrid of fibre-reinforced plastic and steel. The company says the shift could reduce more than 50,000 tonnes of CO2 emissions each year.
JLR has reengineered the crosscar beam, a part that sits behind the dashboard and supports key safety functions. The beam normally uses magnesium or steel, but the new version combines fibre-reinforced plastic with steel. According to the company, removing magnesium - a material with a high carbon footprint - is expected to lower annual emissions by more than 50,000 tonnes of CO₂. This figure is described as comparable to the yearly energy use of about 17,000 homes in the UK.
Role of the Crosscar Beam in Vehicle Safety
The crosscar beam spans the width of the cabin and provides a foundation for components such as airbags. It also contributes to crash protection and helps manage noise and vibration inside the vehicle.
Development Partners and Testing
Initially a research project with suppliers Celanese, CCP Gransden and Petford Group, the material underwent rigorous testing, showcasing that the hybrid structure combines the lightweight properties of fibre‑reinforced plastic with the stiffness and strength of steel. Fibre‑reinforced plastic can also be engineered to absorb energy effectively during impact and when paired with steel, helps maintain the instrument panel’s structural integrity.
Part of JLR’s Wider Sustainability Plan
The company says the redesigned beam reflects goals set under its Reimagine strategy, which focuses on lowering emissions across vehicle development and manufacturing processes.
Thomas Mueller, Executive Director of Product Engineering at JLR, said, "This innovation is a testament to the ingenuity of our engineering, sustainability and supplier teams. By reimagining a component that’s hidden from view, we are able to reduce carbon emission from future vehicles, setting a new benchmark for sustainable architectures for our next generation of luxury cars ‑ without compromising on safety or quality."
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