World Champions “Ready to Race” with KTM and PTC Creo

Start with PTC Creo.
Stop at nothing.

Ideas are your product team's most valuable asset. Unleashing those ideas into real products that set your company apart is where PTC Creo comes in. As the world's most scalable and easy-to-use suite of design software, PTC Creo maximizes every aspect of the design process. From creativity to productivity, teamwork to efficiency.

Ryan Dungey, Ken Roczen, Cyril Despres, Tony Cairoli, Jeffrey Herlings.

If you don’t know these names, you’ve been missing out on some great international motorcycle racing. From the U.S., Germany, France, Italy, and The Netherlands, respectively, these champions and their teams have won more than 223 world championship titles, including 12 victories at the grueling, sun-baked Dakar Rally.

And they’ve done it all sitting atop bikes designed by KTM, a PTC customer.

2013 KTM 690 Duke
2013 KTM 690 Duke

The Mission

Based in Austria, KTM is a leading manufacturer of motorsports vehicles. The company focuses on sport-oriented motorcycles, underscoring its “Ready to Race” philosophy. In short, KTM’s mission is to produce motorcycles with exacting standards of excellence.

“We are driven by constant innovation, week after week, race after race,” says Philipp Habsburg, head of research and development at KTM. “Furthermore, if we see that an innovation works in our racing motorcycles, we quickly introduce it into our production bikes—from our superbikes to our children’s motocross lines. Everything we make is based on product excellence and the engineering behind it.”

Unlike many other manufacturers, KTM engineers everything in-house. That includes the engine, chassis, wheels, etc. Habsburg says that kind of control helps the company optimize every part of the bike, maximizing performance.

Creativity

Design, Simulate, and Optimize
Design, Simulate, and Optimize

The innovation machine at KTM stays revved all the time, says company designer Olaf Seger. “Every model that we release integrates the best of our engineering when we release it. But we never feel we’ve crossed the finish line. Our teams are continuing to dream up the next round of improvements all the time.”

With PTC Creo, that’s not a problem. “We can quickly take any design and easily modify it,” he says. “We can design, simulate, optimize, and modify every aspect of the complete bike in PTC Creo, and this can all be done in just a few hours, compared with the weeks and months it took previously.”

Take the 2013 KTM 690 Duke. It’s the most cutting-edge series production single-cylinder bike of our time. It features a precision chassis with a wealth of outstanding components that make every ride on the 690 Duke unforgettable.

Among the engineering advances on this model is a newly developed counterbalance system that effectively nulls vibration, for a smooth, high-performance ride.

Productivity

As KTM expands its product range, it expands its engineering team. In fact, today the company employs more than 250 designers and engineers.

That’s all good news for KTM, especially since the company uses PTC Creo and is avoiding many of the growing pains other product developers encounter. “With PTC Creo’s flexible modeling approach, everyone can take existing designs and make modifications to improve performance,” says Olaf Seger. “New designers can leverage existing parts, even when the original designer is unavailable.”

Efficiency

Optimizing Chassis and Engine Concurrently
Optimizing Chassis and Engine Concurrently

One of KTM’s secrets to engineering success is its approach to design technology. It is one of the only developers that has standardized on one CAD system for both engine and chassis design. Habsburg says that having the complete 3D model in one format means the teams can work together to optimize their results.

“For example, the team developing the engine is looking for maximum power, they’re looking for maximum air intake, and they want large vents,” he says. “But the chassis design team is looking for minimum wind resistance, so they want a small smooth surface.” Using the same design software, the two teams work more efficiently and find the best overall solutions.”

The KTM 690 Duke is full of those solutions: top-notch performance, minimal internal friction, high fuel economy (61mpg, 26Km/l), 67hp, and 51 lbs/ft of torque. The bike is light too, with a weight of only 329.6 pounds (149.5kg). For the riders, that means sharp handling and punchy performance.

Teamwork

Beyond design and simulation, the KTM team uses several other PTC products across its whole product development process to encourage teamwork, concurrent engineering, and sharing of designs. PTC Windchill manages the processes, concurrent engineering, and workflow across design and engineering. Non-CAD users like manufacturing, marketing, and QA can view models and drawings instantly with PTC Creo visualization capabilities.

“PTC’s products help ensure all key team members can access and use the most current designs” says Habsburg.

The new KTM 690 Duke has been an instant hit, with sales numbers higher than the most optimistic KTM estimate. Check out these results:

  • Developed in record time, just 22 months from first concept to start of production, a 15% reduction in time-to-market compared to the previous generation.
  • Lightest weight in it class, with the most powerful engine.
  • Highest fuel efficiency in its class, with a 10% improvement in fuel consumption compared to the previous generation.
  • New heights of comfort with an all new counterbalance, seat, and frame design.

“Design and engineering at KTM are better because of PTC and their products,” says Habsburg. “The PTC technology has grown right with us to support our needs, helping us reduce time-to-market by 15% in this year’s model range alone.”

Find out more about KTM, the KTM Champions, and PTC Creo.