According to the manufacturer, this development is expected to cut over 50,000 metric tons of CO₂ annually, based on an estimated future annual projection of 270,000 crosscar beams being manufactured when compared to a magnesium crosscar beam. This reduction comes from eliminating magnesium from the crosscar beam, which is highly carbon intensive to produce, in favor of a much lower carbon solution.  

“Redesigning a structural component like this isn’t just a straight materials swap. It’s a complex engineering challenge. Working collaboratively with our suppliers, we had to ensure the new hybrid material met exacting standards for safety, refinement and durability, while delivering a significant CO₂ reduction. It’s a clear demonstration of how research and collaboration can drive meaningful sustainability improvements without compromise,” says Matthew Atkinson, Lead Research Engineer at JLR.

Initially a research project with suppliers Celanese, CCP Gransden and Petford Group, the material underwent rigorous testing, proving that the hybrid structure combines the lightweight properties of fiber reinforced plastic with the stiffness and strength of steel. According to JLR, fiber 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.