In 1977, new emissions regulations and fuel economy pressure threatened to damper the power of performance cars — propelling Reeves Callaway to begin constructing new turbocharger systems from his home workshop for BMW, VW, Porsche, Audi and Mercedes-Benz applications.
Today, with a system-engineered design philosophy and an OEM approach, Callaway Cars, has designed and manufactured performance parts, systems, and complete road cars and race cars for 37 years.
The Connecticut shop has head up engineering projects for Chevrolet, Alfa Romeo, Aston Martin, Land Rover, Mazda, and more.
The team has also created some timeless turn-key sports cars in road car and race car form, including the Callaway C16.
The Callaway C16
If you haven’t seen one, you might be tempted to think of a Callaway as a hot rod. But they’re much more.
“We’re building a powerful car that has a satisfying driving experience with quality materials and great craftsmanship,” says Pat Hodgins, chief engineer at Callaway.
“We use a body style that enhances the aerodynamics of the original car. We send the interior work to Germany for world-class leather work, carpet upgrades and carbon fiber options. All of our products are emissions certified. And we warranty our products, so reliability matters too.”
All Digital Design
And there’s something else: the Callaway C16 is the first project — body, intake, exhaust, aesthetics, etc. — that the company designed completely digitally, with the help of PTC Creo.
Based on the Chevrolet Corvette C6, the Callaway C16 is available in three body styles: the Coupé, the Cabrio (convertible), and the aforementioned Roadster (a convertible that requires drivers and passengers to wear helmets).
“We introduced the coupe after 6 months,” says Hodgins. “The Cabrio came 2.5 months later. And the speedster was ready 3 months after that.”
Releasing three cars in one year? The question is: HOW?
Up-Front Planning and PTC Creo
Hodgins said that with PTC Creo and pre-planning, Callaway engineers could create tooling and plan modifications that supported all three designs right from the start. They could also ensure designs were easy to manufacture, with assembly points in the same place for each car. A task much more difficult back in the home workshop days.
“Using PTC Creo, we can make modifications and adjustments in a time frame you can’t do in the real world. We check clearance requirements, fit and finish requirements, assembly techniques—accessibility of hardware for example. So when we go to make tooling, we’re already tooling for our production parts.”
How much time is Callaway saving with its new digital approach to product development? Hodgins says development is about three times faster now, as previous body styles took about year each to produce.
“For the C16, we cut a lot of time and steps in the system,” says Hodgins.
Give us a call
We know the various Creo configuration possibilities can be confusing. Give us a call and we’ll walk you through the options, compare packages for you, and discuss pricing and licensing issues.
NxRev is the largest PTC reseller on the West Coast—we’re available at 408-986-0200 during normal business hours or contact us here.