CENTER OF COMPETENCE | HIGH-PERFORMANCE AND LIGHTWEIGHT SOLUTIONS

ALL SOLUTIONS FROM ONE SINGLE SOURCE

A Member of the Eberspächer Group 2 | CENTER OF COMPETENCE CENTER OF COMPETENCE | 3

PERFECT DIVERSITY

For 25 years we have been developing innovative solutions with and for our partners. As members of the Eberspächer Group, we can now add other areas of expertise to supplement the experience we have gained in development, prototype production, special series production and motorsport, and we can pass this all on to our customers. To put it into a short context, we offer a comprehensive range of exhaust technology competence.

CENTER OF COMPETENCE: MOTORSPORT: As a centre of competence for high performance applications and light- Motor racing activities include the 24 hour race in Le Mans and the FIA weight systems, Prototechnik’s main focus is on the areas of develop- European Truck Racing Championship, the DTM and the WTCC, but also ment, prototype production and special series production for intake and a wide variety of other formula series. International teams depend on exhaust systems. Working with the Eberspächer Group, Prototechnik the innovative solutions from Schwäbisch Gmünd. Thin-wall technology, creates tailored solutions from concept design and simulation, to light weight and special materials are extremely important factors acoustics and performance optimisation, to prototype production, to which are increasingly being integrated into series production vehicles. 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.

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 | CENTER OF COMPETENCE

A GOOD SETUP

“All competences from one single source.” This philosophy has been affirmed and developed on the basis of numerous projects. We are always willing to tackle new, exciting and difficult tasks – complex special series, manual operations combined with partially automated production processes. From the concept to series pro- duction and beyond. Access to Eberspächer R&D expertise and resources ensures that projects are completed quickly and effectively and to an extremely high quality standard.

Quality and project management Automotive standards (ISO 9001:2008, DFM, D/P-FMEA, risk management etc.) ISO TS 16949 in the planning phase.

Concept and product Prototype manu- Functionality and Purchasing and pro- Special series Spare parts supply development facturing endurance tests duction preparation production

3D/2D CAD in One piece hand- Flow rig Technical purcha- Partially automated 10-15 years in CATIA, PRO-E and made Acoustics & sing production compliance UG Samples for thermodynamics Series production processes combi- with the standards CAE – CFD, FEA functional and Endurance testing – purchasing suppor- ned with manual and longer Acoustics durability testing - component test ted by the Group operations Thermodynamics soft tools benches, engine Series production Batch production Durability – Preseries – and chassis dyna- process planning combined with mechanical, dyna- evaluation of series mometer Quality planning “one-piece flow” mic and thermo- production proces- mechanical ses

One project manager – one point of contact for the entire project, from concept to the spare parts CENTER OF COMPETENCE | 5

PRODUCT PORTFOLIO

We could be known as specialists for specific requirements. We develop and produce intake and exhaust systems for optimal exhaust gas flow, maximum power and torque, exhaust gas aftertreatment and sound engineering. With a great deal of ambition and flexibility, Prototechnik delivers niche-market products in a wide variety of market areas.

OUR PRODUCTS: OUR MARKETS: Intake manifolds and systems Cars, road registered high-performance cars Exhaust systems Motorbikes Exhaust manifolds Commercial vehicles - Turbular/high-performance manifolds Agricultural and construction machinery - Half-shell manifolds Special applications (e.g. ship and boat engines, airplane engines, - Air-gap insulated manifolds stationary engines, defence...) Catalytic converter and DPF systems, ceramic and metal Hybrid and fuel cell vehicles Muffler systems, optionally with valve technology Motorsports and rolled or pressed Complete systems featuring “dual mode” and “air-to-air” We are proud to say that our products can be found on land, on the Exhaust gas heat exchangers water and in the air – anywhere that combustion engines are at work. 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 | CENTER OF COMPETENCE

REFERENCES

Our products are used throughout the entire world. For example, at many international motorsport events.

MOTORSPORT RANGE : CARRERA GT: Production of motorsport components for a wide variety of racing series “Air-to-air” system development and series production of the intake mo- and teams: dule and the entire exhaust system for 2 years Sport, DTM and LMP; BMW Motorsport, WTCC etc.; Mercedes HWA, DTM, F3; Opel DTM; Cup, LMP etc. Motorsport GT3: products: High-performance intake and exhaust manifolds, light-weight Exhaust system development up to start of production within 18 months catalytic converters and silencers, low and high pressure fuel lines, air “Dual mode” (exhaust valve control) for 74 dB(A) with very low exhaust lines, oil lines and welded chassis components backpressure and with light-weight titanium design

SPECIAL SERIES PRODUCTION PROJECTS: MERCEDES -BENZ MCLAREN SLR: System development and prototype production for a variety of manu- A very challenging system development of an exceptional exhaust system facturers, e.g. Ford Focus RS, KTM X-Bow, Mercedes-Benz McLaren packaged in the front end vehicle with “sidepipes”. Series production for SLR, Mercedes-Benz SLK 55 AMG, Opel Zafira CNG, Porsche Carrera GT 5 years GT3 1st and 2nd generation, Touareg & Phae- ton V10, VW Individual. Extra low volume series exhaust system pro- MERCEDES-BENZ SLK 55 AMG: duction for the Zeppelin airship Exhaust system development, testing and series production of several thousand systems per year. Benchmark in the sound (engineering) sector 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 CENTER OF COMPETENCE | 7

HISTORY

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 VHM . Phone: +49 7171 8748-100 Fax: +49 7171 8748-400 [email protected] Printed in Germany. Subject to change without notice. Printed in Germany. www.prototechnik.de 11/2011 Version