A L L S O L U T I O N S F R O M O N E S I N G L E S O U R C E

A Member of the Eberspächer Group

C E N T E R O F C O M P E T E N C E | H I G H - P E R F O R M A N C E A N D L I G H T W E I G H T S O L U T I O N S

2 | C E N T E R O F C O M P E T E N C E

C E N T E R O F C O M P E T E N C E | 3

P E R F E C T D I V E R S I T Y

F o r 2 5 y e a r s w e h a v e b e e n d e v e l o p i n g i n n o v a t i v e s o l u t i o n s w i t h a n d f o r o u r p a r t n e r s . A s m e m b e r s o f t h e

E b e r s p ä c h e r G r o u p , w e c a n n o w a d d o t h e r a r e a s o f e x p e r t i s e t o s u p p l e m e n t t h e e x p e r i e n c e w e h a v e g a i n e d i n

d e v e l o p m e n t , p r o t o t y p e p r o d u c t i o n , s p e c i a l s e r i e s p r o d u c t i o n a n d m o t o r s p o r t , a n d w e c a n p a s s t h i s a l l o n t o

o u r c u s t o m e r s . To p u t i t i n t o a s h o r t c o n t e x t , w e o f f e r a c o m p r e h e n s i v e r a n g e o f e x h a u s t t e c h n o l o g y c o m p e t e n c e.

CENTER OF COMPETENCE:

As a centre of competence for high performance applications and light-

weight systems, Prototechnik’s main focus is on the areas of develop-

ment, prototype production and special series production for intake and

exhaust systems. Working with the Eberspächer Group, Prototechnik

creates tailored solutions from concept design and simulation, to

acoustics and performance optimisation, to prototype production, to

functionality and endurance tests, to special series production and

finally up to spare parts supply.

The business unit also specialises in the production of coolant, oil, fuel

and ventilation lines, EGR cooling systems as well as other vehicle compo-

nents made of pipes and sheet metal. Using and processing special mate-

rials such as Inconel, aluminium and titanium is a part of our daily work at

Prototechnik. It allows us to meet the increasing demands in the various

high performance segments as well as the necessity for more and more

weight reductions. This knowledge is reflected in a number of successful

development, prototyping, special series and motorsport production pro-

jects over more than 25 years of the company’s history.

MOTORSPORT:

Motor racing activities include the 24 hour race in Le Mans and the FIA

European Truck Racing Championship, the DTM and the WTCC, but also

a wide variety of other formula series. International teams depend on

the innovative solutions from Schwäbisch Gmünd. Thin-wall technology,

light weight and special materials are extremely important factors

which are increasingly being integrated into series production vehicles.

LIGHT WEIGHT:

In comparison to conventional stainless steel, titanium facilitates

weight reduction of more than 40 percent. Every ounce of weight

saved serves to reduce CO2 emissions and makes the vehicles

more environmentally friendly. In particular, the company’s special

expertise in the use of new materials makes it possible to develop

innovative exhaust technology products for series production pas-

senger cars as well as commercial vehicles.

4 | C E N T E R O F C O M P E T E N C E

A G O O D S E T U P

Quality and project management Automotive standards (ISO 9001:2008, DFM, D/P-FMEA, risk management etc.)

ISO TS 16949 in the planning phase.

Special series production

Purchasing and pro-duction preparation

Functionality andendurance tests

Prototype manu-

facturing

Concept and product

development

Spare parts supply

“A l l c o m p e t e n c e s f r o m o n e s i n g l e s o u r c e .” T h i s p h i l o s o p h y h a s b e e n a f f i r m e d a n d d e v e l o p e d o n t h e b a s i s o f

n u m e r o u s p r o j e c t s . W e a r e a l w a y s w i l l i n g t o t a c k l e n e w, e x c i t i n g a n d d i f f i c u l t t a s k s – c o m p l e x s p e c i a l s e r i e s ,

m a n u a l o p e r a t i o n s c o m b i n e d w i t h p a r t i a l l y a u t o m a t e d p r o d u c t i o n p r o c e s s e s . F r o m t h e c o n c e p t t o s e r i e s p r o -

d u c t i o n a n d b e y o n d . A c c e s s t o E b e r s p ä c h e r R & D e x p e r t i s e a n d r e s o u r c e s e n s u r e s t h a t p r o j e c t s a r e c o m p l e t e d

q u i c k l y a n d e f f e c t i v e l y a n d t o a n e x t r e m e l y h i g h q u a l i t y s t a n d a r d .

3D/2D CAD inCATIA, PRO-E andUG CAE – CFD, FEAAcousticsThermodynamicsDurability – mechanical, dyna-mic and thermo-mechanical

One piece hand-made Samples for functional and durability testing -soft tools Preseries – evaluation of seriesproduction proces-ses

Flow rigAcoustics & thermodynamicsEndurance testing –component testbenches, engineand chassis dyna-mometer

Technical purcha-singSeries productionpurchasing suppor-ted by the GroupSeries productionprocess planningQuality planning

Partially automatedproduction processes combi-ned with manualoperationsBatch productioncombined with“one-piece flow”

10-15 years incompliance with the standardsand longer

One project manager – one point of contact for the entire project, from concept to the spare parts

C E N T E R O F C O M P E T E N C E | 5

P R O D U C T P O R T F O L I O

W e c o u l d b e k n o w n a s s p e c i a l i s t s f o r s p e c i f i c r e q u i r e m e n t s . W e d e v e l o p a n d p r o d u c e i n t a k e a n d e x h a u s t

s y s t e m s f o r o p t i m a l e x h a u s t g a s f l o w, m a x i m u m p o w e r a n d t o r q u e , e x h a u s t g a s a f t e r t r e a t m e n t a n d s o u n d

e n g i n e e r i n g . W i t h a g r e a t d e a l o f a m b i t i o n a n d f l e x i b i l i t y, P r o t o t e c h n i k d e l i v e r s n i c h e - m a r k e t p r o d u c t s i n

a w i d e v a r i e t y o f m a r k e t a r e a s .

OUR MARKETS:

Cars, road registered high-performance cars

Motorbikes

Commercial vehicles

Agricultural and construction machinery

Special applications (e.g. ship and boat engines, airplane engines,

stationary engines, defence...)

Hybrid and fuel cell vehicles

Motorsports

We are proud to say that our products can be found on land, on the

water and in the air – anywhere that combustion engines are at work.

OUR PRODUCTS:

Intake manifolds and systems

Exhaust systems

Exhaust manifolds

- Turbular/high-performance manifolds

- Half-shell manifolds

- Air-gap insulated manifolds

Catalytic converter and DPF systems, ceramic and metal

Muffler systems, optionally with valve technology

and rolled or pressed

Complete systems featuring “dual mode” and “air-to-air”

Exhaust gas heat exchangers

Other pipe systems (charge-air, coolant, oil and

fuel lines) in steel and aluminium design

Vehicle and chassis components

Vehicle prototype shop

Design and in-house manufacture of jigs and fixtures

We are seeking new challenges. Tell us your problem and let us solve it.

6 | C E N T E R O F C O M P E T E N C E

R E F E R E N C E S

O u r p r o d u c t s a r e u s e d t h r o u g h o u t t h e e n t i r e w o r l d . F o r e x a m p l e , a t m a n y i n t e r n a t i o n a l m o t o r s p o r t e v e n t s .

MOTORSPORT RANGE :

Production of motorsport components for a wide variety of racing series

and teams:

AUDI Sport, DTM and LMP; BMW Motorsport, WTCC etc.; Mercedes

HWA, DTM, F3; Opel DTM; Porsche Carrera Cup, LMP etc. Motorsport

products: High-performance intake and exhaust manifolds, light-weight

catalytic converters and silencers, low and high pressure fuel lines, air

lines, oil lines and welded chassis components

SPECIAL SERIES PRODUCTION PROJECTS:

System development and prototype production for a variety of manu-

facturers, e.g. Ford Focus RS, KTM X-Bow, Mercedes-Benz McLaren

SLR, Mercedes-Benz SLK 55 AMG, Opel Zafira CNG, Porsche Carrera GT

Porsche 997 GT3 1st and 2nd generation, Volkswagen Touareg & Phae-

ton V10, VW Individual. Extra low volume series exhaust system pro-

duction for the Zeppelin airship

PROTOTYPES:

AUDI AG, Quattro GmbH; BMW AG, BMW Motorrad; Daimler cars and

commercial vehicles; Deutz AG; KTM Motorrad; Mowag; MTU; Porsche;

Volkswagen; various system suppliers

PORSCHE CARRERA GT:

“Air-to-air” system development and series production of the intake mo-

dule and the entire exhaust system for 2 years

PORSCHE 911 GT3:

Exhaust system development up to start of production within 18 months

“Dual mode” (exhaust valve control) for 74 dB(A) with very low exhaust

backpressure and with light-weight titanium design

MERCEDES -BENZ MCLAREN SLR:

A very challenging system development of an exceptional exhaust system

packaged in the front end vehicle with “sidepipes”. Series production for

5 years

MERCEDES-BENZ SLK 55 AMG:

Exhaust system development, testing and series production of several

thousand systems per year. Benchmark in the sound (engineering) sector

C E N T E R O F C O M P E T E N C E | 7

H I S T O R Y

1985 Prototechnik GmbH founded

1989 IFT Ingenieurgesellschaft für

Fahrzeugtechnik mbH founded

1995 IFT Prüftechnik GmbH founded

2001 onwards Affiliates move to joint offices in the new

administration building in the Gügling industrial

estate near Schwäbisch Gmünd

Special series production of Mercedes-Benz McLaren

SLR, Porsche Carrera GT, Mercedes-Benz SLK 55 AMG,

Ford Focus RS, Ducati 999 etc.

2003 onwards Affiliated companies are acquired by Ricardo plc.,

Ricardo Deutschland branch

Special series production of Porsche 911 GT3/ RS/ Cup,

Dieselmax land speed world record

2010 BU Prototechnik becomes part of the

Eberspächer family

Prototechnik GmbH & Co. KG

Güglingstraße 68-70

73529 Schwäbisch Gmünd

Germany

Phone: +49 71 71 87 48-100

Fax: +49 7171 87 48-400

info@prototechnik.de

www.prototechnik.de Vers

ion

11/2

011

. VH

MPr

inte

d in

Ger

man

y. S

ubje

ct t

o ch

ange

with

out

notic

e.