DESIGN DEVELOPMENT ENGINEERING TECHNOLOGY INDUSTRIALIZATION

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1 COMPANY INTRODUCTION DESIGN DEVELOPMENT ENGINEERING TECHNOLOGY INDUSTRIALIZATION Lukas Stary February 7, 2017 LUSTACO Group February 7,

2 OUTLINE BASIC DESCRIPTION STYLING & DESIGN PRODUCT DESIGN & ENGINEERING OPTICAL ENGINEERING ELECTRONICS ENGINEERING CAE + CFD ENGINEERING PROTOTYPING ELECTRONICS INDUSTRIALIZATION & JIGS 3D DIGITIZE & MEASURING & REVERSE ENGINEERING REFERENCES SERVICES CONTACT 2

3 BASIC DESCRIPTION LUSTACO engineering team have deep experience more than 15 years with engineering of plastic parts, metal and sheet metal parts, aluminum parts, composites components, hybrid components, optical components, mechatronics, optoelectronic systems and other from styling concept, by development and engineering to prototyping and final serial production. Our significant segment is lighting engineering. We make own Styling and Design, R&D Engineering, Technology, Manufacturing and Production its own lighting systems using LED technology in particular. Projects realize in complex, from initial visualization studies, innovative engineering and technological solutions, including expertise and technical design, including their implementation and guaranteed returns. LUSTACO developing its own LED lighting systems and we are able to develop LED lamps according to the customer requirements. LUSTACO has its own technical team with 10 years of experience in the area of industrial lighting and in recent years we are deal with some LED lighting projects in the automotive industry. We have years of experience with special LED technology R&D projects for European OEMs. We have a deep knowledge of engineering requirements, customer requirements and demands for tools and technologies for automotive and industrial lighting products. We have years of experience in the automotive and manufacturing lighting equipment and products. We have experience in injection molding, metalized and finishes coating. Also, knowledge and experience of the test and the testing requirements, etc. We have the knowledge and experience for production and our strengths are in research and development, design and technology of LED lighting. We can also carry out research and development of innovative products and also architectural lighting. LUSTACO recently deals with a conceptual engineering and development, including design, technology, prototypes and manufacturing LED rear lamps and front LED headlamps for cars such as VW & Skoda, JLR, etc. (Full LED products). We're sorry, but we can not show the actual data and design of this LED products, which are not yet published/release on the common market. But we can show similar LED products like these that are already release on the market - see video: ; 3

4 STYLING & DESIGN CASE STUDIES WITH FEASIBILITY (HOMOLOGATION / RULS) STYLING SURFACES & CLASS A SURFACING STYLING SUPPORT CAS MODELING CONCEPT MODELING 3D CONCEPT STYLING CLAY & HARD MODELING 4

5 STYLING & DESIGN CASE STUDIES 5

6 STYLING & DESIGN CASE STUDY HEAD LAMP 6

7 STYLING & DESIGN CASE STUDY FOR CADILLAC HEAD LAMP & REAR LAMP 7

8 STYLING & DESIGN CASE STUDY FOR CADILLAC HEAD LAMP 8

9 STYLING & DESIGN CASE STUDY HEAD LAMPS 9

10 STYLING & DESIGN CASE STUDY HEAD LAMP / SKODA SUPERB III. 10

11 STYLING & DESIGN CASE STUDY HEAD LAMP / SKODA SUPERB III. 11

12 STYLING & DESIGN CASE STUDY HEAD LAMP / SKODA SUPERB III. 12

13 STYLING & DESIGN CASE STUDY HEAD LAMP / SKODA SUPERB III. 13

14 STYLING & DESIGN CASE STUDY HEAD LAMP / SKODA SUPERB III. 14

15 STYLING & DESIGN CASE STUDY HEAD LAMP / SKODA SUPERB III. - REAL CAR 15

16 STYLING & DESIGN CASE STUDY REAR LAMP / SKODA SUPERB III. 16

17 STYLING & DESIGN CASE STUDY REAR LAMP / SKODA SUPERB III. 17

18 STYLING & DESIGN CASE STUDY REAR LAMP / SKODA SUPERB III. 18

19 STYLING & DESIGN CASE STUDY REAR LAMP / SKODA SUPERB III. 19

20 STYLING & DESIGN CASE STUDY REAR LAMP / SKODA SUPERB III. 20

21 STYLING & DESIGN CASE STUDY REAR LAMP / SKODA SUPERB III. - REAL CAR 21

22 PRODUCT DESIGN & ENGINEERING DESIGN CONCEPT PRE-DEVELOPMENT PROTOTYPING SERIES DEVELOPMENT PRODUCTION & INDUSTRIALIZATION Plastic parts, metal and sheet metal parts, aluminium parts, composites components, hybrid components, optical components, mechatronics, optoelectronic systems and other components. Design Concept of Headlamps, Rear Lamps and Lighting Modules, including Advanced Lighting Systems. Pre-Development of automotive lighting projects for OEM based on agreed technologies (customer demands, technology optimization for final supplier etc.), including driving electronics, production feasibility and legal regulations compliance. optical concept proposal including Prototyping of Headlamps, Rear Lamps and Lighting Modules, including Advanced Lighting Systems for concept vehicles and concepts products, including for verification design. Series Development link to Pre-Development and Prototyping design for final design and transfer products to serial production. Production & Industrialization launch engineering support in series production. 22

23 PRODUCT DESIGN & ENGINEERING INTERIOR Instrument panels, center panels, door panels Seats Restraints, lampshades, handles Roof panels Bottle holders and cups Luxury accessories 23

24 PRODUCT DESIGN & ENGINEERING INTERIOR Instrument panels, center panels, door panels Seats Restraints, lampshades, handles Roof panels Bottle holders and cups Luxury accessories 24

25 PRODUCT DESIGN & ENGINEERING EXTERIOR Bumpers, exterior bars & panels, masks 25

26 PRODUCT DESIGN & ENGINEERING BODYWORK Welded body - a complete platform and bodywork Hobnailed body - hood, doors, rear doors mechanisms Hybrid solutions Body shell metal Body shell - aluminium Platform Body side Cross member Roof systems Front and rear doors Tailgate Locking mechanisms 26

27 PRODUCT DESIGN & ENGINEERING ELECTRO HARNESSES Project planning and management of electric harnesses Design and development of 3D wire harness installation in CATIA V5 2D documentation drawings DMU collision analysis detection & elimination PDM for assembly procedures Development and engineering of harnesses 27

28 PRODUCT DESIGN & ENGINEERING OPTOELECTRONICS LED MODULES - LB & HB FUNCTION FOR HEAD LAMP (circular shape) LED MODULES - LB & HB FUNCTION FOR HEAD LAMP (elliptically shape) 28

29 PRODUCT DESIGN & ENGINEERING OPTOELECTRONICS LED MODULES 3 IN 1 (position light + turn indicator + DRL) BLADE SYSTEM LIGHT PIPE SYSTEM for illustration appearance for illustration appearance 29

30 PRODUCT DESIGN & ENGINEERING MECHATRONICS PORSCHE mechatronic system (actuator) 30

31 PRODUCT DESIGN & ENGINEERING MECHATRONICS Mechatronic system - units 31

32 PRODUCT DESIGN & ENGINEERING MECHATRONICS Drons with camera 32

33 OPTICAL ENGINEERING OPTICAL DESIGN CONCEPT OPTICAL PRE-DEVELOPMENT OPTICAL ENGINEERING - PROTOTYPING OPTICAL ENGINEERING SERIAL PRODUCTION Optical systems for head lamps, rear lamps, led lighting systems, led modules and interior lighting for automotive industry, industrial lighting, completely from basic feasibility analyses to optical design for series productions and including production special optical modules and parts. In-depth know-how of automotive engineering and project requirements, customer specifications & demands, tooling and technologies for lighting products, including testing requirements and launch to SOP 33

34 OPTICAL ENGINEERING Currently we are working on a similar projects (like pictures below). Head Lamp Rear Lamp 34

35 OPTICAL ENGINEERING OPTICAL ANALYSES OF LED MODULES - LB & HB FUNCTION FOR HEAD LAMP Low Beam - Base Unit Projector Unit Low Beam Wide Unit Rectangular Lens High Beam Projector Unit Optical System: Glass Lens + Reflector + 4-Chip LED We count 800 lm on the source Output Luminous Flux 421 lm Optical System: Glass Lens + shield+ 4-Chip LED We count 800 lm on the source Output Luminous Flux 410 lm Optical System: Glass Lens + Reflector + 4-Chip LED We count 800 lm on the source Output Luminous Flux 448 lm 35

36 OPTICAL ENGINEERING OPTICAL ANALYSES OF LED MODULES - LB & HB FUNCTION FOR HEAD LAMP LOW BEAM HIGH BEAM + = + = Total Output Luminous Flux 831 lm Total Output Luminous Flux 1279 lm 36

37 ELECTRONICS ENGINEERING LED lighting modules and LED driving electronics (LDM) Control electronics for mechatronic subsystems Lighting electronic control units (ECU) Schematics, simulations, PCB layout LDMs System with Micro-controllers CAN-Bus and LIN Bus Electronics Systems Drivers for Stepper motors D&D of ECU for Head & Rear Lamps Hardware and Software development for driving and control electronics systems for head lamps, rear lamps, led lighting systems, led modules, mechatronics systems and interior lighting for automotive, industrial lighting, completely from basic feasibility to electronics design for series productions including production electronics components. 37

38 CAE + CFD ENGINEERING Thermal/Flow Analyses (Cooling, Sun Load, Fans) Structural Analyses (Statics) Structural Analyses (Dynamics, Eigen values) Dynamic Analyses (Crash, dynamic behavior, etc.) Special analysis (stability of cut-off line detection) 38

39 PROTOTYPING LOW and MIDDLE PRODUCTION LIMITED SERIES PRODUCTION CUSTOMIZED PRODUCTION PROTOTYPING OPTOELECTRONIC MODULES AND SYSTEMS MECHATRONIC MODULES AND SYSTEMS ELECTRONIC MODULES PCBs LED MODULES PLASTIC PARTS METAL AND SHEET METAL PARTS ALUMINIUM PARTS COMPOSITE PARTS 39

40 PROTOTYPING TRANSPARENT Parts - New technology 3D Print optic parts NEW TECHNOLOGY 3D PRINT OPTIC PARTS 40

41 PROTOTYPING TRANSPARENT Parts - New technology 3D Print optic parts 41

42 PROTOTYPING PROTOTYPING TRANSPARENT PARTS 42

43 PROTOTYPING PROTOTYPING TRANSPARENT PARTS 43

44 PROTOTYPING PROTOTYPING TRANSPARENT PARTS 44

45 PROTOTYPING PROTOTYPING TRANSPARENT PARTS 45

46 PROTOTYPING PROTOTYPING STYLING MODELS FUNCTIONAL PROTOTYPES & MODELS MOCK-UPs RAPID PROTOTYPING INCLUSIVE the final assembly of products like e.g. LED lighting lamps, automotive lamps (headlamps & rear-lamps, mechatronic products and similar products in low series, customized series and prototyping series. 46

47 PROTOTYPING PROTOTYPING STYLING MODELS FUNCTIONAL PROTOTYPES & MODELS MOCK-UPs RAPID PROTOTYPING INCLUSIVE the final assembly of products like e.g. LED lighting lamps, automotive lamps (headlamps & rear-lamps, mechatronic products and similar products in low series, customized series and prototyping series. 47

48 ELECTRONICS ELECTRONIC PARTS PRODUCTION 48

49 ELECTRONICS ELECTRONIC PARTS PRODUCTION 49

50 INDUSTRIALIZATION & JIGS ROBOTIC AND AUTOMATED WORKPLACES 50

51 INDUSTRIALIZATION & JIGS ROBOTIC AND AUTOMATED WORKPLACES 51

52 INDUSTRIALIZATION & JIGS ROBOTIC AND AUTOMATED WORKPLACES 52

53 3D DIGITIZE & MEASURING & REVERSE ENGINEERING DIGITIZING SERVICE MEASURMENT SERVICE 3D DIGITAL MODELING 3D DIGITIZING 3D SCANING 3D SCAN TO CAD CONVERSION REVERSE ENGINEERING 53

54 REFERENCES AUTOMOTIVE LIGHTING DAIMLER TRUCK ACTROS - Head Lamp - 2 versions: halogen + xenon Prototyping - 60 sets Small series production sets 54

55 REFERENCES AUTOMOTIVE LIGHTING JAGUAR C-X16 - Head Lamp 55

56 REFERENCES AUTOMOTIVE LIGHTING CITROEN C3 - Head Lamp 56

57 REFERENCES AUTOMOTIVE LIGHTING CITROEN C4 - Head Lamp 57

58 REFERENCES AUTOMOTIVE LIGHTING SKODA FABIA WRC - Additional lamps 58

59 REFERENCES AUTOMOTIVE LIGHTING SKILLS & EXPERIENCE More than 15 years of experience in development, design and technology of automotive lighting Headlamps, rear lamps, advanced electronics and mechatronics Proficiency with light modules including Bi-Xenon and LED projector units with AFS Experience in LED modules for both headlamps and rear lamps Experience in research and development projects with European OEMs Deep knowledge of automotive engineering, customer specifications, legislative requirements technologies and tools necessary for vehicle lighting development Knowledge of quality requirements, testing procedures and conditions of successful start of production, including start of mass production Experience in project management Knowledge of production technologies and processes Knowledge of prototype manufacturing 59

60 REFERENCES AUTOMOTIVE LIGHTING SELECT LIST OF REALISED PROJECTS Front lights: Bentley BY621, BY624 Mercedes C Audi A6 Audi Q5 Daimler Truck VW 253, VW 019 VW Mexico VW361 Jetta NF hybrid Land Rover L538, L259 Jaguar X150, X250, F-Type Opel Meriva, Junior, Adam Citroen C3, C4 Skoda SK37, SK251, SK46/FL, SK48, Crossover Skoda SK371, SK482 PSA A94, B78, T91, A9 Skoda Motorsport LEDs and Lasers modules Rear lamps: Opel Astra & Insignia Opel Junior 4403 VW Mexico: New Beetle, Jetta A4 redesign VW361/362 Jetta NF hybrid Citroen C4 Ford B299 Fiesta Ford C346 Focus Ford Mondeo Mercedes W164 Volvo Y371 Skoda SK251 Skoda SK370-4 Skoda SK371, SK482 Participation from pre-development to serial production, mechanical engineering and development of part design, AFS systems, LED/ LED DRL modules, Light-Pipe modules, kinematics, Adjusting mechanisms, DRL/FOG/CORNER/STOP function, LED Laser modules. 60

61 SERVICES CAD ENGINEERING OPTICAL ENGINEERING ELECTRO HW ENGINEERING ELECTRO SW ENGINEERING CAE+CFD SIMULATIONS PROTOTYPING LUSTACO SERVICES - OFFER D DIGITIZE & MEASURING & REVERSE ENGINEERING ENGINEERING & MANUFACTURING NONSTANDARD PARTS & ASSEMBLIES ASSEMBLING & PRODUCTION COOPERATION ROBOTIC & AUTOMATED WORKPLACES LOW & CUSTOMIZED PRODUCTION Our services you can order individually, separately or as a whole for your products and projects. We are able to offer fixed price for one engineering loop acc. to input data and the required output data. In engineering loop for every part or for all products we are able to offer fixed price. Our engineering services include complete product development from concepts, styling, design, research and development, engineering, technology, other necessary calculations and analysis. Further including technology, prototyping, manufacturing and support for serial production. For production low and customized series we are able use Plastic Freeforming Technology for production functional plastic parts on the basis of 3D CAD data. Also we offer 3D printing parts of metallic materials on machine Laser Melting System with laser power 400W. We offer CNC inserting PCBs prototyping, low and middle series. We provide engineering and manufacturing non-standard components and assemblies based on customer specifications including assembly of subassemblies. We are able to offer manufacturing cooperation for serial productions for plastic and metal parts and products, optoelectronic and mechatronics products, electronic units including PCBs, etc. Further also engineering, technologies and background for manufacturing process robotic and automated workplaces, robotic welding workplaces, assembly lines etc. 61

62 CONTACT LUSTACO Group 62

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