Jaguar XF Engineering

Underlying the new visual design language, the XF is the product of a new generation of design technology, materials and manufacturing opportunities.

The engineering disciplines behind the XF are as ground-breaking as its new design language. New development processes and computer tools allowed us to work through the programme at a quicker pace than anything previously; new technologies and materials combine strength with lightness; and Jaguar craftsmanship, too, has explored new, exciting contemporary avenues.

Phil Hodgkinson, Jaguar Programmes Director

Virtual Process (VP) and Virtual Series (VS) are the cutting-edge technologies used by Jaguar to take the XF from concept to reality. These techniques use massive computing power and sophisticated modelling programmes to create components and even whole vehicles in the virtual world, before building physical parts and perfecting the systems and processes to manufacture the car. The XF represents the first time that VP and VS tools have been used by Jaguar throughout a complete vehicle programme - from vehicle development, to production feasibility studies, to build planning.

But VP also dramatically improves overall quality, by allowing rapid sign-off of component designs, and eliminating the early physical prototype stage. With VP, when prototypes finally are built, they are intended only to validate what is already known, not to develop areas that are still unresolved. Fully representative vehicles are used for physical evaluation, including on-road testing, crash-testing, hot and cold climate testing, and durability testing. At the same time, the VS programme is working on everything that is needed eventually to build the car – leading to significant improvements in craftsmanship, efficiency, even long-term serviceability.

New technology is also key to the XF’s construction. It was the first programme within Jaguar to use the next-generation CAD programme C3PMG, which combines an all-new CAD-modelling software package with an all-new data-management package – opening the way to exceptional strength without unwanted weight. The design is led by safety needs, especially by the latest side intrusion and SUV over-ride requirements. The reinforced passenger safety cell incorporates new thinking from the lower side rails up.

The XF adopts the latest generation steels, especially in the upper body – including high carbon steels, dual-phase, hot-formed boron steels, and bake-hardened steels to form a vertical safety ‘ring’ around the occupant cell. As well as combining strength with lightness, these steels improve corrosion resistance, by making best use of zinc and improving e-coat paint flow – and new thinking means that in spite of their strength, the XF’s A and B-pillars are impressively slim, to the benefit of both visibility and accessibility. Similarly, the lower sills are the first component on any Jaguar to use incredibly strong, dual-phase DP600 steel.

Second-generation Pedestrian Contact Sensing System – the acclaimed safety system introduced by Jaguar on the XK – is included on the XF (market dependent). This can mitigate pedestrian injury by firing actuators that deploy the bonnet, resulting in a cushioned space between the bonnet and engine hardpoints. The system builds on the technology proven in the XK, using higher resolution sensing and an active rear-hinged bonnet.

Every XF also comes with two-stage driver and front passenger airbags, side and curtain airbags and seat occupant sensing systems to help ensure the airbags work precisely and only as needed in every circumstance. Front-seat occupants also have the added protection of an anti-whiplash system and ‘soft-landing’ technology in the seat-belt retractors to soften contact with the front airbags.

Other changes - many of them made possible by extensive use of the Virtual Process during the development programme - improve craftsmanship by optimising the manufacturing process. Close attention to optical quality creates the smallest, most consistent panel gaps and other new measures improve resistance to minor impacts, making accident repairs easier and less expensive, so contributing to significant cost-of-ownership benefits.