katcon global confidential june, 2015 · 2020-01-27 · presentation contents •company overview...

Katcon Global Confidential

June, 2015


Presentation Contents

• Company Overview

• Facility Locations

• Manufacturing Technologies

• Target Products

• Design & Engineering


Company Overview


History

• Katcon is a global company specialized in the design and manufacture of components and assemblies for the automotive,

off-road, heavy-duty, agricultural and aerospace industries.

• Privately owned company and founded since 1993.

• Supporting OEM´s and Tier1 customers globally.

• In 2012, the company inaugurated Katcon Institute for Innovation and Technology (KIIT) in Monterrey, Mexico.

• During 2014, Katcon launched its new business unit, Katcon Advanced Materials, dedicated to the design and manufacture

of lightweight composite parts

• Katcon is a member of the Aachen Center for Integrative Lightweight Production (AZL) in Germany since 2014.

• In 2015, the company established a cooperation with MTEC for product development, design and engineering of

lightweight composite components and assemblies.


Timeline

• 1993: Started operations building emission control systems – < 10 employees

• 1995: Doubled capacity

• 2000: GM Supplier of the Year

• 2001: GM Supplier of the Year

• 2002: New manufacturing site in Venezuela

• 2007: Absorbed Delphi´s North America converter production

• 2009: Acquired Delphi´s Global Exhaust Business. Katcon becomes a global Company

• 2011: New manufacturing sites in USA and Australia.

• 2012: JV in Korea

New manufacturing site and tech center in China

New R&D center in Mexico, KIIT – Katcon Institute for Innovation and Technology

Katcon Australia receives GM Supplier of the Year

• 2013: New tech center in Luxembourg

JV in China

• 2014: New business unit, Katcon Advanced Materials, dedicated to the design and manufacture of lightweight composites

New manufacturing site in Mexico

Partner of the Aachen Center for Integrative Lightweight Production (AZL) in Germany

• 2015: Cooperation with MTEC for product development, design and engineering of lightweight composite components


Emission controls key customers

6

AvtoVAZ


Emissions platforms participation

7

2016 D2Jxi – Next Gen Volt

2014 P1LL – Cadillac XTS

2014 GMX352 – Impala

2016 A1AC/BC – Camaro

2016 A1BL/SL – Cadillac ATS V

2015 A1LL – Cadillac CTS V



8

2016 F5C – Skid Steer Loader

2014 – LoneStar

2016 F5C – Tractor Loader Backhoe

2016 APEX 1000 – RZR 1000

2016 O1SL – Cadillac CT6

2015 TITAN – Ranger 900



9

2015 M2JC – Spark

2016 E2XX/C1XX – Lacrosse

2016 D2LC – Sonic

2016 E2XX/C1XX – Ragel

2014 C14T – Trax

2015 LFV – Envision


Facility Locations


Global Footprint

LuxembourgMonterrey, Mexico

Chongqing, China

Melbourne, Australia

New Delhi, India

Korea

Aachen, Germany (MTEC/AMAC)

Michigan, USA

Blonie, Poland

Valencia, Venezuela Shanghai, China

Emission ControlsManufacturing Site

Emission ControlsDesign & Engineering Site

CompositesManufacturing Site

CompositesDesign & Engineering Site


Katcon Advanced Materials

• In 2015, in line with its “Vision of a Clear Sky”, Katcon Global has launched a new

strategic business unit, Katcon Advanced Materials, to participate in the future of

lightweight transportation.

• Leveraging it’s position as a supplier of exhaust systems

• High quality operations and workmanship

• Katcon Advanced Materials designs and manufactures lightweight composite

components to reduce vehicle weight and improve fuel efficiency to help OEMs

achieve CO₂ emission targets.

• Carbon fiber based Lightweight Composite Components using HP-RTM.

• Semi structural light weight Thermoplastic Composites parts for underbody closures and

interior parts

• Key Executives:

• Fernando Turner Jr.

• Carlos Garza


Lightweight Composites Trend

Key drivers for lightweight composites usage in the

automotive, off-road and aerospace industry:

• Mass reduction

• Fuel & energy saving

• CO₂ emission regulations target

• Components consolidation

• Reduce tooling cost


Manufacturing Technologies



HP-RTM (High Pressure Resin Transfer Molding)

THERMOFORMING

INJECTION MOLDING

LIGHT-RTM (Light Resin Transfer Molding)


Manufacturing Technology

HP-RTM (High Pressure Resin Transfer Molding)

• High volume production capability

• Fiber reinforced lightweight composite parts production

• Fiber: Carbon, Kevlar, Glass, Natural or Hybrid

• Dosing unit: Epoxy and polyurethane resin

• Clamping unit of 1700Tons

• Max. mold size 2170x1750mm - (30 Tons)



THERMOFORMING


• Long and short fiber reinforced thermoplastic sheets forming

• IR upper/lower multi-zone heating system

• Clamping unit: 100Tons

• Vacuum and air pressure: 5bar

• Max. mold size 1500x1200mm – (20 Tons)



INJECTION MOLDING


• Tie-bar-less machine design

• Clamping unit: 220Tons

• Fiber load capacity: 30% - 40%

• Injection shot capacity: 607cm³

• Max. mold size 980x830mm

• Unloading Viper robot and conveyor



LIGHT-RTM (Light Resin Transfer Molding)

• Low volume production capability

• Fiber reinforced lightweight composite parts production

• Fibers: Carbon, Glass, Kevlar, Natural or Hybrid

• Dosing unit: Epoxy resin w/heating system


Rapid Prototyping Technologies



ADDITIVE MANUFACTURING

STAINTLESS STEEL 3D PRINTINGCOMPOSITES 3D PRINTING

PLASTIC 3D PRINTING

• Carbon Fiber

• Kevlar

• Glass Fiber

• Nylon

• ABS


Target Products


Exterior Body Panels (Class A)

• Hood, Roofs and Tailgate Assemblies

• Side Panels

• Fender Assemblies

• Removable Hardtop Assemblies

Underbody Components

• Underbody Shields

• Fuel Tank & Engine Shields

• Underbody Reinforcements

• Engine Covers

Structural Components

• Bumper Beams

• Chassis Reinforcements

• Seat assemblies

• Hybrid Battery Module Covers

Interiors & Components

• Flooring

• Climate Controls & Center Consoles

• Door Panels

• Multifunctional switches

Products


Design & Engineering


Katcon Advanced Materials

Engineering capabilities

Katcon has established a cooperation with several European

companies with a strong and experienced knowledge in

composites designing, engineering and manufacturing.

Engineering Development Process


Katcon Partnerships

26

- Process Development

- Prototyping

- Network

- Process Equipment

- Tooling

- Business Development

- Commercial Proposals

- Design & Engineering

- Product Development


MTEC-Katcon Partnership

MTEC

• Design & Engineering capabilities based in Aachen, Germany

• Foundation in 1991

• Spin-Off from the Institute of Plastics Processing (IKV) at RWTH Aachen

• More than 20 years of experience working with composites

• Interdisciplinary teams of experts

Extract of Customers:


MTEC-Katcon Partnership

28

Product definition

Product development

Simulation & Calculation

Test & Trials Industrialization

CAE Competences

FE-Analysis –

component design

Moldflow simulation Light SimulationFlow Simulation (CFD)

Structural optimizationDrape simulationCrash-Simulation

Integrated Simulations

Engineering Process

• Plastics technology• Fluids mechanics• Material knowledge• Simulation technique• Lightweight engineering

• Construction technology• Simulation & calculation• Test & trials• Tool technology• Industrialization

• Automotive• Medical• Mechanical engineering• Electronics


AZL-Katcon Partnership

• Most complete and advanced composites research center

• Excellence in all required competences for lightweight composite solutions

• More than 700 scientists and 1,000 student workers


Global Headquarters

Av. Manuel Ordoñez 601

Col. Centro, Santa Catarina NL

Mexico CP 66350

Contacts

We build the future of

lightweight transportation

Fernando Turner

Executive Vice-President

[email protected]

Dr. Michael Effing

European Representative

[email protected]

Glenn Sandgren

Business Development, NA

[email protected]

Andreas Büttgenbach

Engineering Project Manager

[email protected]

Manufacturing Plant

Servidumbre de Paso 3199

Parque Industrial FINSA

Santa Catarina NL

Mexico CP 66144

Carlos Garza

Operations Manager

[email protected]

Ashish Diwanji

Business Development, NA

[email protected]

Frank Kohlmann

Business Development, EU

[email protected]

www.katcon.com/advancedmaterials/

[email protected]

mailto:[email protected]







http://www.katcon.com/advancedmaterials/



THANK YOU!

katcon global confidential june, 2015 · 2020-01-27 · presentation contents •company overview...

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