In today’s highly competitive market, success depends on bringing dramatic, high quality products to market quickly and efficiently. Roush’s Prototype Services group plays a critical role in supporting that effort, providing OEM customers with development support that effectively fuses technology and engineering. From the design studio to the shop floor, from concept and show vehicles to complete prototype vehicle build programs, from co-located engineering programs to production plant retrofit campaigns, Roush’s prototype services exemplify our corporate mission: to provide OEM customers with high quality, innovative support…from start to finish.
Our facilities, services and processes have been specifically designed to maximize efficiency and flexibility. We can scale our services to support projects ranging from the development of unique components to complete vehicle assembly. Roush’s skilled technicians combine traditional craftsmanship with the most modern technologies in state-of-the-art development sites.
Services and amenities offered include:
Vehicle Build/Garage Services
- Certified technicians
- Over 1,453,496 square feet of shop space
- Electronically-secured development garages
- Full vehicle instrumentation
- Off-site development support
Metal Fabrication
- Vehicle chassis, body and component modification
- Laser cutting
- Low volume manufacture of prototype parts
Hard Model Fabrication
- REN foam and wood modeling
Engine Development
- Machining
- Engine Build
- Cylinder Head Development
Advanced Composites
- Prepreg carbon fiber
- Epoxy wet lay
- Vacuum bag
- Oven and autoclave cure process
Soft Trim
- Vehicle Camouflage
- Interior Trim
- Seating
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Modeling
- 3 electronically-secured design studios
- Tarus 5-axis milling
- Clay modeling
- ATOS digitizing system
- Portable floor model coordinate measuring machine
Wiring and Electronics
- Design, development and low-volume manufacturing of custom circuit boards
- Documentation in GERBER 274X/Protel/Circuit Maker/Trax Maker
- SMT and through-hole circuitry
- Repair and rework existing circuit boards
- Embedded micro-controllers
- Package design and packaging (for model shop applications)
Projects Include:
- Active lighting systems
- Stepper motor control systems
- LED lighting systems
- Instrumentation electronics
- Fuel pump control systems
- Automated show car systems
- Vehicle simulation
- Weapons simulation
- Auxiliary battery control systems
- Boost management systems
- Signal generation (A/D, D/A, F/V)
- Oil temp management systems
- Monitoring systems (e.g., Trans Status Boxes)
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