Design Develop Build Race Win

Engineering Services

Design Engineering l Modeling & Simulation I Electronics I Manufacturing

Testing & Development l Robotics l Software Solutions l Program Management
 Design Develop Build Race Win

Pratt & Miller

Engineering

Prepared to win in ALL we do

“We believe in our commitment to our customers… we have to win.”
- Jim Miller, President

For over 20 years Pratt & Miller has used the world’s legendary race tracks as technology
proving grounds to develop many race programs, including Corvette Racing, the most
successful team in the history of the American Le Mans Series.

“The success and the passion that we have for motorsports permeates throughout the
entire building.”
- Gary Pratt, Vice President

As a dominant force in professional motorsports, the team has used a proven formula
of integrating people, processes, and technologies, advancing Pratt & Miller’s world-
renowned motorsports operations, into the innovative, full-service engineering and low
volume manufacturing company it is today. With over 200 employees, Pratt & Miller is
proudly serving a global customer base including those in the Defense, Automotive, and
Powersports industries.

Winning the prestigious “24 Hours of Le Mans” seven times is a testament to the
company’s dedication to being the best in all we do. The most stringent quality
requirements are met, within the most time-compressed deadlines. No project leaves the
facility that is anything less than beyond customers’ expectations – ensuring that Pratt &
Miller will be the creator of tomorrow’s standards.
 CAPABILITY NAME
ISO 9001:2008
CERTIFIED
A Michigan Small Business

VALUE

Engineering Services
YEE SATISFACTION

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Our commitment to attracting and retaining

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talented and driven people, developing robust

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processes, and investing in advanced technology,

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results in superior value and satisfaction for our

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ADVANCED TECHNOLOGY
customers.
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MER SATISFAC T

“There is a reason we always turn to Pratt & Miller for highly technical projects
and rush projects. We can always rely on Pratt & Miller to complete the project
as fast as possible a nd it is always done right the first time.”
- A satisfied Pratt & Miller customer

Table of Contents
1 Design Engineering

3 Modeling & Simulation

5 Electronics

7 Manufacturing

9 Testing & Development

11 Robotics

13 Software Solutions

15 Program Management
 Design Develop Build Race Win

Design Engineering
At Pratt & Miller, we have excellent, proven design resources that can take an
idea from concept to a well-engineered solution. Using the latest Computer Aided
Engineering (CAE) technologies, our designers work alongside our machinists,
fabricators and engineers throughout the development process, ensuring delivery
of the highest quality product.

Industrial Design
Capabilities:

• Concept Creation
Brand development
Sketching
Brainstorming
Styling

• Prototyping and Physical Model Creation

Rapid prototyping
Class A surfacing
Clay modeling

• Human Factors
Market research
Ergonomics
Human Machine Interface (HMI)
Safety

• Visualization
Animations
Realistic CAD rendering

Technology:

• ALIAS
• Rhino
• Photoshop
• Showcase
Design Engineering

1
Computer Aided Design (CAD)
Capabilities:

• Conceptual design
• Parametric solid and surface modeling
• Class A surfacing
• Packaging/architecture design
• Reverse engineering
• Weight reduction

Technology:

• NX
• SolidWorks
• CATIA
• Pro/ENGINEER

Structural Analysis & Simulation

Capabilities:

• Static linear analysis

• Non-linear analysis
• Kinematic and dynamic analysis
• Composite structure analysis
• Optimization
• Impact and crash analysis
• Durability/fatigue analysis

Technology:

• HyperWorks
• ANSYS
• Laminate tools
• Optistruct
• Genesis
• Radioss
Design Engineering

2
 Design Develop Build Race Win

Modeling & Simulation

Pratt & Miller’s world renowned modeling and simulation capabilities allow
us to develop solutions virtually and optimize performance prior to building
hardware. By front loading the product development process with modeling
and simulation, Pratt & Miller is able to compress the overall project timeline
and improve the performance of the first prototypes. Once physical hardware
is undergoing testing, modeling and simulation is used to refine the system
performance, quickly analyze alternatives, run sensitivity studies, and correlate
test data. Utilizing the latest advancements in computer hardware and software
run by expert analysts, Pratt & Miller can predict and develop vehicle and
system performance for attributes such as ride, handling, mobility, acceleration
performance, durability, structural performance, blast analysis, crash analysis,
safety system performance, aerodynamics, HVAC, and cooling management.

Vehicle Dynamics
Capabilities:

• Track lap time optimization

• System analysis and optimization
• H igh-level code routines, database
applications, MATLAB applications and
GUI development
• Data analysis applications
• Test data analysis and correlation
• Ride, handling and mobility analysis
• I ntegration of supplier generated
subsystems (control systems, tires, etc.)
• Component load generation
• D etailed system modeling of brakes,
clutches, and power steering

Technology:

• A
 DAMS, ADAMS/Car and ADAMS/Chassis
• CarSim
• Dymola
• Optimization using HEEDS/MDO
Modeling & Simulation

3
Survivability
Capabilities & Technology:

• S
 ystems engineering approach applying
extensive knowledge of all vehicle systems
• E
 xpertise in theoretical shock physics analysis
• A
 bility to conduct and correlate
appropriate experiments
• P
 roprietary explicit software code with
continuous development to improve
prediction of blast events
• A
 ccess to one of the largest, privately owned
super-computing systems in the U.S. used to
conduct large-scale full-3D calculations

Applications:

• System solutions for occupant protection

• Underbelly blast
• Ballistics
• Vehicle structure development
• Add-on protection kit development
• Material evaluation
• Manufacturing process evaluation
• Energy absorbing device development
• Floor development
• Seat development
• Restraint development
• Injury prediction
Computational Fluid Dynamics
Capabilities & Technology:

• E
 stablished processes to generate
high-quality grids rapidly on complex
configurations
• Proprietary tools to improve overall grid
quality and increase local grid refinement
• Proprietary flow solver software and
post-processing tools to simplify the
analysis of large 3D data sets
• Super-computing system to conduct
Modeling & Simulation

large-scale full-3D calculations

• Test execution including component
prototyping, scale and full-size wind tunnel
testing, and on-road testing

Applications:

• Drag reduction for fuel economy

• Downforce management for performance
• Airflow through radiator, coolers,
brake ducts
• Engine bay temperature management
• Underbody air flow 4
• Interior heating and cooling performance
 Design Develop Build Race Win

Electronics
The foundation of Pratt & Miller’s electronics department has evolved from the
competitive world of motorsports to include many industries with the same
commitment to exactness, functionality, and reliability. Through the latest
technologies and manufacturing strategies, our experienced team is on the
cutting edge of development in Motorsports, Defense, Automotive, Powersports
and Product Innovation. Our electronics group provides comprehensive control
systems, advanced electrical engineering, electronic hardware design, and in-
house manufacturing.

Electrical Engineering
Capabilities:

• Vehicle power distribution systems

• Vehicle data & information networks
• Circuit design & PCB layout

Technology:

• MATLAB
Simulink
Stateflow
• PSpice
• Eagle PCB design

Control Systems & Embedded Software

Capabilities:

• Algorithm design
• Human Machine Interfaces (HMI)
• Rapid control system prototyping
• Autonomous vehicle control systems
• C
 omplex multi-domain system modeling
and model-based control systems
• Vehicle dynamics control systems

Technology:
Electronics

• MATLAB
Simulink
Stateflow
• Mototron/Motohawk
• Custom solutions

5
EV/HEV Engineering
Capabilities:

• Architecture modeling & simulation

• V
 ehicle and component architecture
trade studies
• C
 omplete system prototyping and
vehicle integration
• V
 ehicle and energy system
supervisory controllers

Technology:

• MATLAB
Simulink
Stateflow
• Mototron/Motohawk
• Eagle PCB Design

Electrical Manufacturing
Capabilities:

• A
 nalog and digital electronics design
and testing of circuit boards, electronic
devices and mechatronics
• D
 esign and engineering of custom
MIL-SPEC/motorsport wire harnesses
and cable assemblies
• E
 mbedded micro-controller PCB layout
and assembly
• H
 igh-voltage/hybrid electric wiring
assemblies

Technology:

• MIL-SPEC hardware
• Autosport
• Production intent
Electronics

6
 Design Develop Build Race Win

Manufacturing
Pratt & Miller specializes in low-volume, prototype manufacturing with
capabilities that include rapid prototyping, CNC machining, metal fabrication,
composite tooling, and precision assembly. Under one roof, we offer
seamless integration of manufacturing with design, engineering, testing and
development, and quality assurance. This integrated process ensures the
highest quality products are delivered within an accelerated time frame.

Machining
Machining Processes:

• 3D CNC milling
• CNC turning
• ID/OD grinding
• Jig grinding
• E
 lectrical Discharge Machining
(EDM)
• Splining
• Shot peening
• Honing

Machined Materials:

• Tooling board
• Aluminum
• Steel
• Stainless steel
• Titanium
• Magnesium
• Brass
• Plastics
• Tungsten

Fabrication
Capabilities:

• Complete chassis fabrication

Manufacturing

• Full vehicle prototype builds

• TIG - MIG - ARC welding
• Sheet metal forming
• Tube notching
• Tube bending
• Sheet metal laser cutting
• Sheet metal water jetting
• Fixturing
• Engine header fabrication
• Sandblasting
• Powder coating

7
Composites
Capabilities:

• Prepreg or wet layup

• Honeycomb core (aluminum & Nomex)
• F
 oam core (short run molded cores
available)
• Proprietary lost core RP process for
ducting or tubular structures
(Patent pending)
• Post-cure oven for controlled
heat cycling
• Resin Transfer Molding (RTM)
• V
 acuum Assisted Resin Transfer Molding
(VARTM)
• Prototype and short production runs
• Mold manufacturing and prep onsite
• H
 ard tooling, composite tooling,
metal molds, and bladder molding
• Clay modeling

Assembly
Capabilities:

• Full prototype vehicle assembly

• Electrical system assembly
• Hydraulic and line assembly
• Vehicle modernization
• Data acquisition installation

Quality Assurance
Pratt & Miller’s quality management system
is certified to the ISO 9001:2008 standard.

Equipment and processes:

Manufacturing

• Z
 eiss CONTURA G2 10/12/6 CNC CMM
with a VAST XT active scanning sensor
running CALYPSO
• F
 aro Edge 12’ portable CMM arm with
a Laser Line Probe for 3D scanning of
complex surfaces
• F
 aro Quantum 6’ portable CMM arm
running CAM2 Q, and a FARO Gage
portable CMM arm running CAM2 Gage
• Rockwell digital hardness tester
• N
 on-destructive testing and inspection
methods including magnetic particle
inspection and fluorescent dye 8
penetrant inspection
 Design Develop Build Race Win

Testing & Development

Pratt & Miller’s testing & development department is composed of qualified
engineers with diverse real-world testing experience. Utilizing state of the art
software tools, specialized test equipment, and efficient product development
planning our team can accommodate a wide variety of projects. From custom
test benches to full vehicle build and validation, our team is prepared to support
your testing needs.

Component, System, & Full Vehicle Testing

Core Capabilities:

• S uspension system development

and tuning
• V ehicle dynamics, durability, and
validation
• I nstrumentation and data acquisition
• S hock dynamometers
• P roduct showcasing and benchmarking
• F leet/event management and support
• A dvanced data analysis and correlation
• K inematics & compliance testing
• A erodynamics and cooling system testing
• F atigue testing and correlation
• H ydraulic systems test bench
• D ynamometer testing
• F ailure mode analysis

Full Vehicle Dynamics and Development

Services:

• R ide quality and handling analysis

• I terative design, simulation, and
testing process
• E xperienced vehicle dynamic evaluations
• M ass inertia testing
• S even post shaker rig analysis
• C ertified test drivers/engineers
• E fficient test plans minimize cost
Testing & Development

and time
• A ccess to all major testing sites
• T ransporters and mobile testing
headquarters

9
Specialized Testing Support:

• T est bench design and manufacturing

• S pecialized software controls
• L ightweight, modular DAQ systems
• P rofessional quality wiring harnesses
• A ccelerated survivability/reliability testing
• P roduction launch support
• I ndependent 3rd party evaluations
• M ilitary vehicle testing
• E xtreme mobility and off-road
development & testing

Tire Testing & Modeling

Capabilities and Resources:

• C omplete program for tire test planning, execution and model generation
• E xperience with test machinery worldwide
• C ustom software development for testing, data visualization, data analysis and
model fitting
• T ire model fitting capability including Magic Formula, Pacejka or 3rd party
black box models
• C ustom tire model creation for specific vehicle dynamics applications
• L ibrary of existing tire data
• T ire model integration to 3rd party simulation packages such as ADAMS,
Carsim, Dymola
Testing & Development

10
 Design Develop Build Race Win

Robotics
Pratt & Miller understands the value of robust, reliable systems, and robotics
applications are no exception. The Pratt & Miller robotics team consists of
highly technical and trained engineers from an array of engineering disciplines
and technical specialties. This vertical integration of departments, combined
with a multidisciplinary approach, provides us the unique ability to offer
solutions that consider all aspects of complex electromechanical systems. Our
team of engineers is dedicated to providing high-end performance mobility
solutions capable of exceptional vehicle stability in the harshest terrain.

Applications:

• System integration
Pratt & Miller’s electronics and robotics teams are uniquely suited to integrate
existing sensors and cameras into any intelligent transportation system
• Autonomous controls
Experts in developing high performance vehicle mobility controllers
• U
 nmanned platforms
Design and development of ground robotic mobility platforms that are low
cost, lightweight, tough, and modular
Robotics

11
Technology:

• Custom mechanical design &

manufacturing using:
NX
SolidWorks
CATIA
Pro/ENGINEER
CNC machining
Composite materials

• Custom electronics using:

PSpice
Eagle PCB CAD
Atmel, PIC, and TI microcontrollers

• C
 ustom software/firmware
development using:
C/C++
Python
Java
Verilog
Linux
OpenCV Image Processing

Robotics

12
 Design Develop Build Race Win

Software Solutions
Pratt & Miller’s software development team provides professional-grade software
development services to support internal engineering and data management
initiatives. By utilizing robust design, documentation, development, and quality
assurance processes, we can rapidly develop enterprise-level software solutions
that are highly effective and configurable for a wide range of clients. Pratt &
Miller’s software solutions group strives to take the cutting-edge engineering
technology developed by our race programs and package it into easily deployable
applications in a variety of industries.

PM-VES (Pratt & Miller - Vehicle Engineering System)

Parts Database:

• A comprehensive parts database to store and manage the various components used
by the vehicle fleet during the development process
• Ability to create part types, with each part type having an unlimited number of
user-defined attributes
•  Time-varying part attributes allow users to track changes in part attributes as they
degrade or are modified
• Allows tracking of part wear, as well as inspection and rebuild activities

Vehicle Development and Testing:

• D
 evelopment and testing activities organized as a series of events, sessions
and outings
• D
 iscrete vehicle tests organized by time to assemble full development and
configuration history of vehicle
• Ability to recall complete vehicle configuration at any point in the development cycle

PM-LTS (Pratt & Miller - Lap Time Simulation)

Features:

• 13 DOF (Degrees of Freedom) vehicle model that can be used to predict lap times
• Fully dynamic solver capturing true dynamics of sprung and unsprung masses
• Support for both open loop and closed loop events
• Support for Pacejka tire models - 94, 94, 2002
• Asymmetric chassis, non-linear kinematics, compliance, non-linear spring dampers,
Software Solutions

and bump rubbers

• Configurable driver model
• Smart shifting powertrain model
• 3D engine map - torque versus RPM and throttle position
• Automatic track creation from lateral acceleration and velocity, GPS, or Pi Survey
• Detailed track specification including elevation, banking, friction, high frequency
corner specific road input, and atmospheric conditions
• Multiple aerodynamics definition from simple coefficients to 3D map as function of
bounce/pitch/roll/yaw
• Support for Design of Experiments (DOE) functionality
• Support for post-processing and post-process interface to Pi Toolbox

13
PM-DOE (Pratt & Miller - Design of Experiments)

Analysis:

• A
 bility to import DOE response surface results and organize them into unlimited
experiment sets
• U
 nlimited configuration sets allow users to study different factor settings
• U
 nlimited chart option to plot responses
• A
 bility to cascade responses of one experiment as factors to another
• E
 xport option to export analyzed data to other applications

Charting:

• 9
 different chart types including:
Paretos
Polynomial
Surface
Trends
• V
 iew data in both two and three dimensional formats
• W
 ork on single or multiple chart views

Optimization:

• Q
 uick determination of the optimum design criteria
• R
 esponse optimization while varying a few or all the factors
• S
 imple constraints allow user to specify ranges the factors must fall within
• C
 omplex constraints allow user to constrain factors together so that they are linked
together
• M
 ultiple DOE support such that they can be optimized at the same time with the
results of one simulation being input to a different simulation

PM-CST (Pratt & Miller - Combined Simulation Toolset)

Features:

• S ingle, integrated toolset that combines essential basic vehicle engineering activities
• F ull-vehicle suspension geometry assembly from component geometry
• K inematic analysis
• S teady-state load transfer analysis
CAPABILITY

• Provides
 both a simple, grid-based view of geometry and setup parameters for easy
Software NAME

comparison, as well as user-customizable setup pages

• A ll output content, both plotting and data grids, is also customizable, allowing users
to define the most appropriate views for their application
• I nteractive 3D view of assembled suspension allows users to visually inspect setups
Solutions

and simulation results

• All
 setup data, as well as chassis components and their associated geometries are
stored in an efficient parts database to eliminate the need for managing individual
data files
• Analysis
 results can be exported to generic XML and Excel formats, but can also be
exported to ADAMS and Mitchell data file formats
• T ight integration with the PM-VES databases is also available for clients who are
already using PM-VES to manage component and setup data
14
 Design Develop Build Race Win

Program Management
Pratt & Miller program management engineers provide project planning,
estimation, implementation, execution, and ongoing support. Translating user,
customer, and stakeholder needs into programmatic requirements, the Pratt &
Miller program managers usher projects through design, development, testing
and production on-time and within budget.

As the primary liaison between the various internal departments, the Pratt &
Miller program manager draws upon our strengths to maximize efficiency and
effectiveness between disciplines. Our program managers also direct external
functions to achieve program and customer objectives, from inception to
completion.

By establishing processes and procedures based on industry best practices, the

Pratt & Miller program manager will:

• E stablish and manage internal and

external resources to execute
projects successfully
• C oordinate an organized and efficient
project plan based on deliverables
• Evaluate and manage program risks
• C oordinate with internal team on program
priorities and issue resolution
• M aintain program timeline for
communicating key tasks, dependencies,
and deliverables
• I mplement project control systems for
managing schedules and budget
• P rovide clear and consistent
communication with client on
project status
Program Management

15
Pratt & Miller Contact
Pratt & Miller Engineering
29600 W. K. Smith Drive
New Hudson, MI 48165

Phone: (248) 446-9800

Fax: (248) 446-9020
www.prattmiller.com
Pratt & Miller Engineering is located just off Grand River
on William K Smith Dr. between Milford Rd. and Wixom Rd.

Pratt & Miller Engineering (Trident location)

29201 Trident Indsutrial Drive
New Hudson, MI 48165
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