Development of combustion engines, hybrid drivetrains and drive systems – from concept and 3D-printed prototypes through to production transfer.
HC-Concepts Engineering GmbH
Nußdorf (Weitwörth Industrial Estate) · Salzburg · AustriaNew on Amplifa
About HC-Concepts
HC-Concepts is a development company for mobile drivetrains based in Nußdorf near Salzburg. The company designs, engineers and develops high-performance engines, clutches, transmissions and hybrid transmissions for the motorcycle, automotive, aviation and marine sectors as well as for robotics and motorsport. Its best-known project is the single-cylinder engine of the BMW Motorrad G 310 R (25 kW), which is produced in series in India. The value chain spans concept design and calculation, production-ready design, prototype construction including in-house 3D printing in plastic (FDM) and metal (SLM with two EOS M290 units and one SLM 500 Quad Laser), testing on two engine test benches (150 kW each) and a vehicle roller dynamometer (up to 250 kW), as well as industrialization and production transfer at the manufacturer, among other places in Taiwan, India and China. For the production transfer of a complete motorcycle engine, prototype sand-cast housings were converted to die-casting-ready designs; aluminum and titanium parts are printed in the powder bed process with 30–120 micrometer layer thickness and post-processed in the company's own workshop. The 18-person team is organized into the departments of Design, Project Management, Development Engineering, and Purchasing and Administration.
- Site
- Nußdorf / Salzburg
- Processes
- Engineering – concept design & calculation (engine/transmission development, hybrid transmissions), Engineering – design (3D casting designs, production-ready machining drawings), Drivetrain technology – development of customized drive systems (integrated drives,, Prototyping – procurement of prototype parts, assembly of pilot and pre-series engines,, 3D plastic printing (FDM) – fit verification, functional and design verification, 3D metal printing (Selective Laser Melting, SLM) – powder bed process, 30–120 micrometers, Post-processing of 3D-printed parts – removal of support structures, surface grinding,, Mechanical workshop – fixture construction for test bench setups and modification work
- Materials
- Aluminum, Titanium, Plastic (3D printing FDM), Steel (steel spring, one-piece steel connecting rods), Selective Laser Melting (3D metal printing), 3D plastic printing, Steel, Plastic
- Certificates
- ISO 9001:2015, VDA ISA 5.0.3, EN ISO 9001:2015, Corporate mission statement, In-house test bench testing, Optical component measurement, Damage analysis
- Founded
- 2003
- Employees
- 18
- Industries
- Motorcycle industry, Automotive, Aviation, Marine / Jet ski / Foilboard, Motorsport, Robotics
- 01
Concept design & calculation
- 02
Design (3D casting designs, machining drawings)
- 03
3D plastic printing (FDM)
- 04
3D metal printing (SLM)
- 05
Post-processing (heat treatment, blasting, grinding)
- 06
Prototype assembly & procurement
- 07
Test bench testing
- 08
Quality control & measurement
- 09
Industrial Engineering & production transfer
Materials & Processes
Selective Laser Melting (3D metal printing)
Powder bed process with 30–120 micrometer layer thickness for prototypes and small series in aluminum and titanium.
3D plastic printing
Cost-effective fit, functional and design verification in the early development phase.
Aluminum
Material for 3D-printed complex components such as cylinder heads and two-stroke cylinders.
Titanium
For high-strength 3D-printed components as well as motorsport valves and connecting rods in engine construction.
Steel
Used for valve springs and one-piece steel connecting rods in engine and transmission concepts.
Plastic
Material for FDM-printed parts used for functional and design verification.
Heat treatment
Used as a post-processing step for 3D-printed parts as well as a documented production specification for series manufacturing.
Locations
Nußdorf
ATHeadquarters: development, workshop, test benches, 3D printing
- Materials
- Aluminum, titanium, steel, plastic
- 2× EOS M290 (SLM, build volume 250×250×325 mm, 400 W fiber laser)
- SLM 500 Quad Laser (build volume 500×280×365 mm, 4× 700 W fiber laser)
- FDM 3D printer
- Dynamic engine test bench API 150 kW
- Eddy-current engine test bench API 150 kW
- Vehicle roller dynamometer Dynojet 250i (up to 250 kW, headwind up to 180 km/h)
- AVL blow-by measuring device
- High-pressure parts washing system
- Mechanical workshop
- Measuring machines & optical component measurement
Components & Services
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Engineering – concept design & calculation (engine/transmission development, hybrid transmissions)Engineering | – | – | – | – | – |
| Engineering – design (3D casting designs, production-ready machining drawings)Engineering | – | – | – | – | – |
| Drivetrain technology – development of customized drive systems (integrated drives,Engineering | – | – | – | – | – |
| Prototyping – procurement of prototype parts, assembly of pilot and pre-series engines,Assembly | – | – | – | – | – |
| 3D plastic printing (FDM) – fit verification, functional and design verificationAdditive | – | – | – | – | Plastic |
| 3D metal printing (Selective Laser Melting, SLM) – powder bed process, 30–120 micrometersAdditive | – | – | – | – | Aluminum, Titanium |
| Post-processing of 3D-printed parts – removal of support structures, surface grinding,Surface | – | – | – | – | Aluminum, Titanium |
| Mechanical workshop – fixture construction for test bench setups and modification workMachining | – | – | – | – | – |
| Engine test benches – performance development, functional testing, aggregate tests (dynamicTesting | – | – | – | – | – |
| Vehicle roller dynamometer Dynojet 250i – dynamic power measurements up to 250 kW, endurance testingTesting | – | – | – | – | – |
| Quality control – measuring machines, optical component measurement, damage analysis (microscopes),Testing | – | – | – | – | – |
| Industrial Engineering – industrialization & production transfer (manufacturing, quality andEngineering | – | – | – | – | – |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 3D metal printer (SLM) | EOS M290 | 2 | Build volume 250 x 250 x 325 mm, 400-watt fiber laser | 2016 | Nußdorf, Gewerbestraße 10 |
| 3D metal printer (SLM) | SLM Solutions SLM 500 Quad Laser | 1 | Build volume 500 x 280 x 365 mm, 4 x 700-watt fiber laser | 2022 | Nußdorf, Gewerbestraße 10 |
| FDM 3D printer (plastic) | – | – | – | – | Nußdorf, Gewerbestraße 10 |
| Dynamic engine test bench | API 150 kW | 1 | 150 kW | – | Nußdorf, Gewerbestraße 10 |
| Eddy-current engine test bench (brake and aggregate test bench) | API 150 kW | 1 | 150 kW | – | Nußdorf, Gewerbestraße 10 |
| Vehicle roller dynamometer with eddy-current brake and headwind blower | Dynojet 250i | 1 | Power measurements up to 250 kW, headwind blower up to 180 km/h | – | Nußdorf, Gewerbestraße 10 |
| Blow-by measuring device | AVL | – | – | – | Nußdorf, Gewerbestraße 10 |
| High-pressure parts washing system | – | – | – | – | Nußdorf, Gewerbestraße 10 |
Additional services
Reference customers
Quality & Certification
Quality control includes measuring machines for critical components, optical component measurement, a high-pressure parts washing system, and powerful microscopes for damage analysis and documentation. Certification to EN ISO 9001:2015 and VDA ISA 5.0.3 for data security.
| Evidence | Nußdorf |
|---|---|
| EN ISO 9001:2015 | |
| VDA ISA 5.0.3 | |
| Corporate mission statement | |
| In-house test bench testing | |
| Optical component measurement | |
| Damage analysis |
History
- 2003
HC-Concepts founded by Ing. Claus D. Holweg.
- 2016
Investment in two EOS M290 3D metal printing machines (SLM).
- 2022
Investment in an SLM 500 Quad Laser machine; publication of the corporate mission statement dated 23.02.2022.
Development of the BMW Motorrad G 310 R single-cylinder engine (25 kW) with series production in India; production transfer of a complete motorcycle engine in Taiwan, India and China.