Katcon Global Confidential
June, 2015
Presentation Contents
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Company Overview
Facility Locations
Manufacturing Technologies
Target Products
Design & Engineering
Katcon Global Confidential
Company Overview
Katcon Global Confidential
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.
Katcon Global Confidential
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
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Katcon Global Confidential
Emission controls key customers
AvtoVAZ
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Emissions platforms participation
2016 D2Jxi – Next Gen Volt
2014 GMX352 – Impala
2014 P1LL – Cadillac XTS
2016 A1AC/BC – Camaro
2016 A1BL/SL – Cadillac ATS V
2015 A1LL – Cadillac CTS V
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Emissions platforms participation
2016 F5C – Skid Steer Loader
2016 F5C – Tractor Loader Backhoe
2014 – LoneStar
2016 APEX 1000 – RZR 1000
2016 O1SL – Cadillac CT6
2015 TITAN – Ranger 900
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Emissions platforms participation
2015 M2JC – Spark
2016 D2LC – Sonic
2016 E2XX/C1XX – Lacrosse
2016 E2XX/C1XX – Ragel
2014 C14T – Trax
2015 LFV – Envision
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Facility Locations
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Global Footprint
Aachen, Germany (MTEC/AMAC)
Blonie, Poland
Michigan, USA
Korea
Chongqing, China
Monterrey, Mexico
Luxembourg
New Delhi, India
Shanghai, China
Valencia, Venezuela
Emission Controls
Manufacturing Site
Emission Controls
Design & Engineering Site
Composites
Manufacturing Site
Composites
Design & Engineering Site
Melbourne, Australia
Katcon Global Confidential
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
Katcon Global Confidential
Lightweight Composites Trend
Key drivers for lightweight composites usage in the
automotive, off-road and aerospace industry:
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Mass reduction
Fuel & energy saving
CO₂ emission regulations target
Components consolidation
Reduce tooling cost
Katcon Global Confidential
Manufacturing Technologies
Katcon Global Confidential
Manufacturing Technologies
HP-RTM (High Pressure Resin Transfer Molding)
THERMOFORMING
INJECTION MOLDING
LIGHT-RTM (Light Resin Transfer Molding)
Katcon Global Confidential
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)
Katcon Global Confidential
Manufacturing Technology
THERMOFORMING
• High volume production capability
• 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)
Katcon Global Confidential
Manufacturing Technology
INJECTION MOLDING
• High volume production capability
• 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
Katcon Global Confidential
Manufacturing Technology
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
Katcon Global Confidential
Rapid Prototyping Technologies
Katcon Global Confidential
Manufacturing Technologies
ADDITIVE MANUFACTURING
COMPOSITES 3D PRINTING
STAINTLESS STEEL 3D PRINTING
• Carbon Fiber
• Kevlar
• Glass Fiber
• Nylon
PLASTIC 3D PRINTING
• ABS
Katcon Global Confidential
Target Products
Katcon Global Confidential
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
Interiors & Components
• Flooring
• Climate Controls & Center Consoles
• Door Panels
• Multifunctional switches
Structural Components
• Bumper Beams
• Chassis Reinforcements
• Seat assemblies
• Hybrid Battery Module Covers
Katcon Global Confidential
Design & Engineering
Katcon Global Confidential
Engineering Development Process
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.
Katcon Global Confidential
Katcon Partnerships
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Process Development
Prototyping
Network
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Process Equipment
Tooling
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Business Development
Commercial Proposals
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Design & Engineering
Product Development
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MTEC-Katcon Partnership
MTEC
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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:
Katcon Global Confidential
MTEC-Katcon Partnership
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Plastics technology
Fluids mechanics
Material knowledge
Simulation technique
Lightweight engineering
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Construction technology
Simulation & calculation
Test & trials
Tool technology
Industrialization
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Automotive
Medical
Mechanical engineering
Electronics
CAE Competences
FE-Analysis –
component design
Crash-Simulation
Drape simulation
Structural optimization
Moldflow simulation
Flow Simulation (CFD)
Light Simulation
Integrated Simulations
Engineering Process
Product
definition
Product
development
Simulation &
Calculation
Test & Trials
Industrialization
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AZL-Katcon Partnership
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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
Katcon Global Confidential
Contacts
We build the future of
lightweight transportation
Global Headquarters
Av. Manuel Ordoñez 601
Col. Centro, Santa Catarina NL
Mexico CP 66350
Manufacturing Plant
Servidumbre de Paso 3199
Parque Industrial FINSA
Santa Catarina NL
Mexico CP 66144
Fernando Turner
Executive Vice-President
fernando@katcon.com
Carlos Garza
Operations Manager
carlos.garza@katcon.com
Dr. Michael Effing
European Representative
michael.effing@katcon.com
Ashish Diwanji
Business Development, NA
Ashish.diwanji@katcon.com
Glenn Sandgren
Business Development, NA
glenn.sandgren@katcon.com
Frank Kohlmann
Business Development, EU
frank.kohlmann@katcon.com
Andreas Büttgenbach
Engineering Project Manager
a.buettgenbach@katcon.com
www.katcon.com/advancedmaterials/
advanced.materials@katcon.com
Katcon Global Confidential
THANK YOU!
Katcon Global Confidential