Katech Corporate
Katech Prototyping

PROTOTYPING

Katech maintains a full-service CNC facility that provides one-off designs and small runs of prototypes that assist corporate clients with design revisions, functionality, and cost-reduction strategy.

Katech can build from metal, plastic, or composite materials. We are known for quick turnaround and extreme quality.

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Katech CNC resources include a Centroid A560, Brute 3124-V 5-Axis VMC; Haas VF5 5-Axis VMC; Fadal 15XT-4-Axis VMC; Haas VF3 4-Axis VMC; Fadal 4020-4-Axis VMC; a Haas VF2-SS-4-Axis VMC; Haas VF2 3-Axis VMC; Haas SL-20T Lathe with C-axis; Haas SL-10 Big Bore Lathe; and Haas SL-20- Lathe, with bar feeder and live tooling.
 

MANUFACTURING

Katech provides short- and long-run manufacturing services delivering engine and vehicle components to the most demanding specifications. Whether it’s a thousand parts or a hundred thousand – from simple piece parts to complex prismatic parts requiring four- and five-axis machining – Katech manufacturing consistently delivers on time and to the highest level of quality.

ENGINE BUILD

Katech provides OEMs engine development and testing solutions that can significantly reduce product development time and cost.

Katech’s rigorous assembly process covers pre-assembly measurements, clearances, assembly procedures, torques, adhesives, lubricants and other aspects of engine assembly. Traceable records are maintained for future reference. Quality control is maintained through progressive inspection and procedures.

CLICK HERE to see all the steps to the build of a Katech engine

Disassemble, wash and inspect parts
Crack check using Magnaflux (ferrous metals) or Zyglo (non-ferrous metals) if necessary
Chase all threads in cylinder case and clean
Measure main bores, line hone if necessary
Measure lifter bore clearance
Measure cylinder bore
Hone cylinder bores using deck plates
Measure bore finish with profilometer
Weigh pistons, connecting rods, rod bearings, pins, locks and rings to determine crankshaft bobweight
Balance crankshaft
Polish crankshaft journals
Tack weld crankshaft trigger wheel
Hone piston pin bores and connecting rod small end
Polish piston pins (excl. DLC-coated pins)
Deburr piston round wire locks
Measure ring lands for back clearance
Deburr piston ring ends
Gap piston rings
Measure main journals with air gauge
Measure big end of connecting rods with air gauge, hone if necessary
Size main bearings with air gauge
Measure connecting rod bolt stretch
Size rod bearings with air gauge
Measure crankshaft endplay
Measure piston pin endplay
Measure connecting rod side clearance
Check piston to deck height
Deck block if necessary

CC piston dome volume
CC cylinder head chamber volume
Deck heads if necessary
CC intake port volume
CC exhaust port volume
Measure valve guide clearance
Measure valve spring pressure and coil bind
Check valve spring retainer to seal clearance
Polish camshaft
Measure camshaft specs with EZ Cam
Degree camshaft
Measure piston-to-valve clearance
Measure valve radial clearance
Measure vertical valve drop
Measure camshaft endplay
Measure lifter preload to determine pushrod length
Calculate compression ratio
Torque all fasteners to spec
Document all measurements and torques in engine build book
Perform engine dynamometer validation

Other capabilities as needed:

Hot hone (cylinder bore honing at operating temperature)
Piston ring land flatness measurement to the millionth of an inch
Hardness testing
Bore cylindricity measurement using PAT Incometer
Valvetrain dynamics testing
Cylinder head flow testing
Dynamometer durability testing and track simulation
Engine calibration (MEFI4)

Engine Testing

ENGINE TEST

Katech maintains three Engine Dynamometers Cells geared for performance applications. Two are rated over 12,000 RPM and 1000 horsepower, the third cell is rated at 10,000 RPM and 800 horsepower. All cells operate with multiple fuels, allowing calibration over a wide-range of applications.

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The Katech Motoring Cell measures parasitic losses for a range of engine components. The Katech Valvetrain Cell provides physical testing, from cam to valve actuation. The Katech Fuel Flow Cell tests fuel system configurations prior to first application.

The six test cells are also used to provide several other critical engine tests, including cylinder pressure and engine air flow.