Hinge pillar assembly having an inner retainer panel, and method of manufacturing the same

A method of manufacturing a hinge pillar assembly for a vehicle, the method comprising:

• casting a hinge pillar panel with a high pressure direct casting process including a die set having an upper ejector die half disposed vertically above a lower non-ejector die half, to define a casting interlock feature disposed on an interior surface of the hinge pillar panel wherein the interlock feature includes a cored boss;
• positioning an acoustic foam layer about the casting interlock feature such that the casting interlock feature positions the acoustic foam layer relative to the hinge pillar panel;
• and
• attaching an inner retainer panel to the hinge pillar panel by fastening the inner retainer panel to the hinge pillar panel with a fastener, with the acoustic foam layer disposed between the interior surface of the hinge pillar panel and the inner retainer panel.