Fair enough...
cliffs:
1. We bring in a development car and get it up on a lift to examine the design and construction of the factory system. From there we decide what products to develop based on a few things; where we believe there to be room for potential improvements in power, sound, weight, etc. as well as what the market is looking for.
2. We run baseline dyno tests to use as a control figure for our power improvements using our DynoJet 424 XLC-2 linked all-wheel-drive dynamometer with dedicated Bapro dyno fans as well as auxiliary fans on any additional air intakes (as needed).
3. After getting baseline dyno runs we remove the factory components and measure all of the critical areas, taking careful note of mounting points, interference points, heat shields, etc. We use our CMM Romer 3D Digitizing Arm to create a three-dimensional CAD model of the parts from which we will craft our new designs.
4. Once a design is worked out, we then determine which pieces of equipment will be needed in order to manufacture the individual pieces. In the case of the F12 Sport Cats in this video, we used our HAAS CNC Vertical Lathe (we also have a HAAS vertical Mill) to machine out these flanges, and our Unison Breeze Electric CNC Mandrel Bender to bend the tubing (we are one of maybe 4 companies with a bender of this caliver... the others being Airbus, Boeing, Lockheed Martin... you get the idea).
5. With the specifics and manufacturing details worked out, we then begin building a prototype. This prototype is usually a combination of machined pieces, 3D-printed components, and hand-fabricated pieces.
6. The prototype then gets stress tested for strength and is test-fit on the car for initial "modified" dyno testing.
7. If the sound and performance gains are up to our standard (and the standard of our clients), we move into the final phase of manufacturing, where we create a bend path to be used on our mandrel bender. We source premium-quality T304L stainless steel tubing in 10’ and 20’ raw sections so that we can create one-piece seamless bends for maximum flow and performance. We are also the world’s second-largest importer of authentic HJS catalysts, which is are widely regarded as the best performing and most reliable cat that money can buy.
8. The catalyst endcaps are attached using one of our orbital welders, while the O2 sensor bungs and other weld points are all fabricated and assembled by hand during final construction.
9. Once all of the testing and individual component manufacturing is complete, A fixture (or Jig) is made using the same aforementioned equipment to guarantee that precise fitment is repeatable every time, for every customer. our highly-skilled welders and fabricators then take over, assembling the final products to be sold worldwide.
Here is a quick breakdown of the various pieces of equipment that we use for our in-house development and manufacturing:
o Flow Mach4 XDCNC 5-Axis Waterjet | The Mach 4 Series contains the most advanced waterjet technology in the industry for unmatched versatility and capability; offers a 6' x 12' cutting envelope.
o Unison Breeze CNC Electric Mandrel Tubing Bender | Ultra accurate, all-electric mandrel tube bending; compatible with a variety of tubes and pipes including, but not limited to, stainless steel, DOM round steel, chromoly and more. Compatible with tubing up to 3.00" (76mm) diameter.
o Haas VF2 CNC Vertical Machining Center | Industry-leading accuracy and precision for repeatable CNC machining of parts and components.
o Haas ST-20 CNC Turning Center | Industry-leading accuracy and precision for repeatable CNC machining of parts and components.
o Bystronic XPert 150-Ton CNC Press Brake | CNC-controlled backstops with multiple bending stations allow for high volume and quick turn-around.
o CNC Plasma Cutter | Cut metals as thin as .030”-.500” with minimal slag and kerf deviations.
o CNC Laser Engraver | Capable of engraving and/or marking area within a 7" x 7" square or a 10" diameter circle.
o Stratasys Dimension Elite 3D Printer | Rapid prototyping and product development with a build envelope of 8" x 8" x 12" (203mm x 203mm x 305mm).
o Bridgeport Manual Mill
o Acer Manual Lathe
o Robotic TIG Welding Lathe | Precision orbital tube welding with quick turn-around and consistent results
o Romer CMM 7-Axis 3D Digitizing Arm | Generate digitized 3D models of existing components forproduct development and prototyping