Callaway Carbon Presentation erc

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COMPANY PRESENTATION
&
CAPABILITIES
Here is Competence.
I would like to take this opportunity to introduce Callaway Carbon, Inc - one of the Callaway Companies
Callaway Carbon offers our clients a comprehensive solution for design, engineering, tooling, and production of
composites. With a worldwide staff of more than 130, we offer exemplary parts, managed production, and cost
effective execution. In summary: competence.
The Callaway Companies has a rich history of innovation in engineering and manufacturing working with and for some
of the best and brightest companies worldwide.
For more than twenty-five years we have concentrated our efforts on composites, and specifically carbon fiber
composites.
Five years ago we brought a very capable RTM system from our German partners to our US facility. The KRTM
System produces very accurate and repeatable carbon fiber components. The Kramer Resin Transfer Molding
system leads the industry in producing structural carbon parts with fully integrated features in one swift molding step.
We appreciate this opportunity to present our capabilities and look forward to discussing how Callaway Carbon may
assist.
Ely Reeves Callaway
Chief Executive Officer
The Callaway Companies
CALLAWAY FACILITY
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20,000 sq. ft Facility
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Callaway Carbon, Inc.
2441 Pullman Street, Santa Ana CA 92705
714-845-3400
www.callawaycarbon.com
2 miles from John Wayne Airport
Engineering Resources
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Utilizes the latest design software solutions from PTC,
such as Pro/ENGINEER® Creo
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Spaceclaim 2012+
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Alphacam R2012
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Full manufacturing engineering support
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Component design support
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Partner Support -
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CMM Dimensional Inspection
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White Light Scan
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Laser Scan
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FEA - NASTRAN
KRTM proprietary process software
Quality Assurance
Callaway Carbon Quality Statement
To be an internationally recognized manufacturer and supplier of high quality
carbon fiber components, associated equipment and services by fulfilling our
commitments to our customers and our employees through continuous
growth and improvement.
Santa Ana Facility
Main Fabrication Area
Callaway Carbon Equipment
Curing Oven 600F - 6’H x 4’W x 7’L
Used for Post Curing of final molded parts
5-Axis CNC Mill - 144”X x 60”Y x 20”Z
Used for machining tooling and
machining final product foam cores
KRTM Equipment
KRTM (Kramer Resin Transfer Method)
Leads the industry in producing structural carbon
parts with fully integrated features in one swift
molding step.
‣ Class A surface finish, all sides
‣ Automated sensor-based process control
‣ Process metrics (time, temp, pressure, flow)
automatic documentation on each part
produced
‣ Traceable and accurate content and mass
control
‣ Precision dimensional control
‣ Closed mold tooling
‣ Dry carbon preforms with low density cores
‣ Fully integrated hard points
KRTM PROCESS
Dry Fiber
Reinforcement
Pressure
Resin
Injection
Preform with core
and inserts
Close Mold
Vacuum
Finished
Component
KRTM Tooling
KRTM Tooling
Projects
Medical Table For MRI Machines
Projects
Clamp Assembly
Rohacell machined foam
core with integrated
fasteners
Projects
Vehicle Hood
Rohacell
machined
foam core
Projects
Removable Hard Top
Projects
Structural Connector
Projects
Support Assembly
Projects
Seat Base
Projects
Lamborghini Center Console
Core Details
Fastener Integration
Surface Details
Part Inspection
Callaway Carbon utilizes Hexagon Metrology in
Lake Forest, CA for Dimensional inspection of
completed components. Inspection Processes
include -
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•Romer Arm
•CMM
•Leica Laser Scanner
•White Light
Sample Material Testing
Callaway Carbon utilizes Exova Testing Labs in Orange county
CA, for material testing such as -
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•Tensile Strength Testing
•Sheer Strength Testing
•Bond Strength Testing
•Peel Strength Testing (cored laminates)
•Fastener Pull-Out Strength Testing
•FAR 23.853 Aircraft Interior Flammability Testing
Contract Support
Although Callaway Carbon’s core business is to support our customers with “Build to Print” services we also offer additional
support in the following areas -
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• Engineering - process, part and tool design
• Research & Development - part design/testing
• Prototyping - fully operational - partial or full scale
• KRTM Licensing - For clients managing proprietary production, Callaway Carbon supplies
automated machinery, support, and know-how through a support contract.
Industry Expos
Thanks
Thank You For Your Time.
We invite your questions and discussion.
We look forward to working together.
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Adrian Corbett
Operations Manager
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Callaway Carbon
2441 Pullman Street
Santa Ana CA 92705
main: 714 845 3400
direct: 714 719 0419
[email protected]
www.callawaycarbon.com