NICHE VOLUME AUTO
& EV MANUFACTURING
AUTO MANUFACTURING SOLUTIONS

IN-HOUSE BUILD,
COMMISSIONING & TESTING

ROAD AND RACE APPLICATIONS

Providing the expertise and facilities that allow all conventional, hybrid and full electric motorsport powertrains and vehicles to be manufactured, built, commissioned, and tested.

Internal Combustion & Electric Engines

Whilst the future is electric, many motorsport series still rely on a gasoline internal combustion engine, the in-house build facilities are separated into two main areas.

In the first, high-volume exhaust extracts have been fitted to allow engines of up to 600+hp to run at full power.

The second is reserved for electric-only vehicles and as such houses dedicated battery build facilities, plus the tools and safety equipment needed to create and commission electric vehicles. The two workshop facilities can be configured flexibly, due to a range of two and four post ramps, plus a number of portable units.

CAD / CAM

To support the vehicle build activities, a full range of metalwork facilities are present on-site, from manually-controlled machines to the latest CNC machining centres linked through to CAD systems enabling rapid turnaround of designed parts.

Welding

Welding stations are provided so that subframe assemblies, roll cages, etc can be fabricated on-site to ensure that the best results can be obtained when completing customer vehicles.

Additive Manufacturing

Complex shapes and structures can be created using a number of different materials with advanced additive manufacturing.

Commissioning

As the variety of technology that is installed on a vehicle increases, the vehicle commissioning process will inevitably become more complex. 

Examples of complexity include ADAS systems (for driver assistance features including blind-spot detection etc), driver monitoring systems, etc.

Calibration

Our facilities include the necessary calibration aids to complete the build of these systems into vehicles and their subsequent calibration.

RELATED CAPABILITIES

Additive Manufacturing

Offering the manufacture of complex shapes and bionic structures using a number of different materials with advanced auto additive manufacturing.

Design


Highly experienced automotive design engineers, delivering electronic, mechanical, concept, prototype and electric motor design solutions.

testing


In-house/track testing facilities and our dedicated team creates the environment to develop highest quality solutions in the quickest time.

Applications Engineering

Supporting your application with the technical expertise required to ensure correct integration in line with the specification.

FREQUENTLY ASKED QUESTIONS

One example for Daimler between 2009 and 2011, where over 2,000 smart electric drivetrains were produced from a dedicated Zytek facility at the ‘Smart Fortwo’ assembly plant in Hambach, France.

See our Smart Fortwo case study.

Yes.

To present our capabilities as an engineering partner to major OEMs, we created an electric vehicle based on the Lotus Elise. This included torque vectoring (opposed to Tesla’s approach of a single motor driving a conventional gearbox), electric motor and inverter technology and the benefit of two motor systems on handling.

See our concept design solutions page.

Most manufacturing of mechanical assemblies is performed by our close network of specialist partner companies, but we have a range of CNC engineering centres in-house that are utilised full time for tasks where turnaround time is imperative.

Yes, as well as a traditional metalworking workshop.

Yes, in closely controlled environments to ensure product quality and performance. 

On the electronics side, bare PCBs are bought in, and from that point on, internal resources can be used to produce finished components. 

For electric machines, the same is true – starting with bought in laminations cut to our own profiles simulated in the design tools, Zytek wind stators, and assemble rotors in house, completing the assembly with a range of low-speed measurement tests to ensure the product meets quality and performance targets.

Also see our ‘off the shelf’ electric machines that are available.

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