At Katalyst Engineering Services, we continually strive to drive innovation by deftly utilizing these resources, changing the issues encountered by various industries and fields with potential solutions.
At Katalyst Engineering Services, we continually strive to drive innovation by deftly utilizing these resources, changing the issues encountered by various industries and fields with potential solutions.
When performance, durability, and manufacturability intersect, innovative engineering is required. A major client from the construction and power generation sector approached Katalyst Engineering to develop a 260kW (349 hp) engine power pack concept. The power pack was intended for rugged construction site use and needed to deliver on performance, packaging optimization, and engineering feasibility.
Katalyst Engineering, a leader in product engineering services, was chosen for their expertise in 3D CAD modeling, design for manufacturability, and their reputation for first time-right solutions.
The client’s expectations were clear but demanding:
With these challenges on the table, Katalyst Engineering adopted a structured, agile-based product development process to ensure accuracy, flexibility, and scalability.
The team initiated the project using the step file of a 7.8L engine, meticulously analyzing it for spatial constraints, thermal flows, and mechanical behavior. This foundational analysis was key to aligning the client’s goals with real-world manufacturing constraints.
Using UG-NX, one of the most powerful CAD software tools in the industry, our engineers crafted detailed 3D models for each subsystem. Native CAD data was integrated with SAP-ECTR for enterprise-wide visibility and digital thread management.
Katalyst generated multiple modular layout configurations, focusing on ventilation optimization, component heat tolerance, and service access. Each design was tested virtually for structural integrity and manufacturability.
Leveraging JIRA for project management, collaborative reviews were conducted across mechanical, thermal, and manufacturing teams. Iterative changes were made based on peer feedback and feasibility analyses.
With the design approved, the team provided:
These deliverables ensured a seamless transition to prototyping and production.
The final design package was completed with zero engineering change requests, highlighting the accuracy and robustness of the process. The complete 260kW power pack system was ready for real-world testing and deployment.
Through Katalyst’s structured process and simulation-driven approach, all parts were manufactured and assembled without design rework, ensuring faster go-to-market.
By redesigning the subsystem layout for efficient airflow, the power pack achieved enhanced heat transfer—a vital factor for prolonged field performance in hot environments.
The engine pack was validated both virtually and physically passing shop tests and live-field trials with flying colors. This ensured real-world durability and compliance.
From child part design to final 3D assembly, every detail was crafted to improve manufacturability and lifecycle performance. See the included visuals showcasing critical subsystem CADs and final installations.
This integration of design, data, and collaboration tools is a hallmark of Katalyst Engineering’s process-driven methodology.
Conclusion
The 260kW Engine Power Pack Concept Design project is a showcase of Katalyst Engineering’s commitment to engineering excellence, agile development, and product reliability. The solution not only met but exceeded client expectations—delivering superior performance, manufacturability, and long-term value.
For organizations seeking end-to-end mechanical design services, Katalyst Engineering stands as a trusted partner that transforms ideas into validated, production-ready products.
Need help understanding our services in depth? Our team of experts will specify everything you require. Tap on the Contact Us button and connect with our team today!
admin
11th June 2025
