STONE — Art of Manufacture
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The promise of an outstanding exhaust system is fulfilled by the skill of the craftsmen, the team’s experience, proper tooling, and technology.
Employing the latest technologies and finest materials, STONE exhausts are optimized for performance by highly trained and experienced welding professionals. Patent accomplishments and high caliber of these systems are indicative of the company’s devotion to extreme detail in exhaust production. Partnering its 23 years of expertise, STONE swears by the latest tooling and instruments in the automotive industry. Their systems are constructed and perfected with 3D scanning machines, state-of-the-art bending machines, mechanical welding arms, and more.
Reverse Engineering & 3D Scanning
In the product development cycle of a STONE exhaust, 3D scanning is a vital process in fabricating the various parts of an exhaust system. The exhaust constitutes a major part of a vehicle, both in size and in function. Reverse engineering and 3D scanning lay the foundation of the development process, the basis to retrieving structural analyses.
Prior to developing the model for the exhaust, STONE extracts the information needed to build the ideal exhaust for that particular engine. Engineers 3D scan the OEM car parts with every angle scrutinized. This attention to detail helps engineers make sense of the various functionalities of these parts and identify hidden weaknesses. The data derived is used to analyze factors such as the pipe diameter, route, and degrees of the bending angles. This aids in rectifying any margin of error to achieve unequaled levels of precision.
3D Simulation Software
During the prototyping of the exhausts, the 3D simulation software simulates the exhaust gas flow movement and thermal and pressure rise zone. Rich data is obtained to implement improvements in the exhaust design until it has accomplished optimal performance. This method also ensures every exhaust is 100% OEM fitment.
Premium Quality Metal
To complement the production process, STONE selects the most premium materials and metals that can elevate the ability to absorb harmful micro particles to create an end product of optimal performance and engine efficiency. The stainless steel used is aircraft-grade SUS304, also known as T304. Stainless steel is distinguished for its non-corrosive properties resistant to rust, heat, and time, preventing leaks or premature wear and tear.
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Valvetronic System
Many drivers who upgrade to valvetronic exhausts want to enjoy the freedom of controlling the exhaust valves. STONE valvetronic system gives users instant ability to monitor the valves’ opening and closing. This in-house system forgoes the conventional design of complicated wiring and rubber inside the valve which is prone to aging. This ensures longevity. Furthermore, the system can be easily installed simply by connecting it to the vehicle’s OBD-2 port.
Simple Installation
The remote control accompanying the system comes with three modes: ON, OFF, and AUTO. The ON and OFF buttons allow the freedom to switch modes instantly during swift changes in road patterns or driving situations. The specialized AUTO mode has a predefined RPM based on on-road tests which allows customizing the valves’ opening and closing. The valves open and close automatically according to the RPM that the user sets. This allows total control and freedom of the exhaust system.
Genuine BMW OEM Motors
All of STONE’S exhausts utilize genuine BMW motors and connectors. Though costly, they support long-lasting performance even in extreme driving conditions. Furthermore, all transmission components are designed through the CNC Process which fortifies a structurally sound exhaust system throughout.
7-Axis CNC Bending Machine
In the aerospace and defense industries, companies employ 7 axis CNC Bending Machines; this is the ultimate machine designed to attain optimal levels of precision. It is no small investment as it is powerful in its operational abilities and potential to achieve a desired geometric form in the shaping of an exhaust. The other challenge is in its operation as the handler is expected to master the techniques required to successfully maneuver the machine.
Mastering this state-of-the-art precision tool comes with its rewards. This aerospace technology prevents airflow obstruction and welding fracture issues while supporting the seamless construction of exhaust systems. With this investment, STONE is able to surpass automotive industry’s standard of perfection to a stupendous 98% roundness with an accuracy error of under 0.025mm, as well as maintain the wear of the outer bore at only 25% at 180°.
Direct Spot Welding
At the final stage of the exhaust production cycle, STONE performs direct spot welding on the exhausts to perfect complex, hard-to-reach angles.
Crisscross and Overlapping Welding Technique
The flange between the turbo and the downpipes reaches extreme temperatures (800℃ to 1100℃) which creates stress on the connection point. By utilizing both welding techniques to increase the width and penetration of welds, STONE is able to vamp up the endurance and tolerance of these connection points, thereby creating a robust and sustainable exhaust structure.
Mechanical Welding Arm
Mechanical welding arms are a notable investment because of their ability to attain greater precision and penetration compared to manual welding. The engineers monitor direct spot welding using the mechanical welding arm to intensify the durability of each exhaust. As a result, these exhausts come to life with the combination of outstanding materials, processes, and technology.
