How Corning transformed diesel emissions control with aluminum titanate technology (Part 3/3)

Thomas Leonhard, now Light Duty Director, and Lutz Kercher, now DVP & Commercial Director, Corning Environmental Technologies with one of the first DuraTrap AT filters in 2005
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As Corning Environmental Technologies celebrates 20 years of cleaning the air with light duty diesel particulate filters (DPFs), the business is reflecting on how a critical product innovation progressed. In the final article of this three-part series, we look at challenges at the verge of product launch and the product’s lasting impact.

By 2004, Corning’s aluminum titanate filters were poised to revolutionize diesel emissions control, but commercialization presented its own challenges. While Corning’s research team in Sullivan Park, Corning, New York, worked tirelessly to refine the technology, commercial and account teams collaborated closely with strategic customers to ensure Corning delivered not just a functional product, but a solution that met emission standards in a more cost-effective and efficient way than competing silicon carbide (SiC) offerings.
 

The hard work paid off: By the targeted deadline, Corning delivered the first samples of Corning® DuraTrap® AT filters to customers for testing in April 2004, receiving positive feedback. This success drove adoption of DPF systems to Corning’s new DuraTrap® AT product, fueled by customer confidence in Corning’s ability to scale this product for high-volume manufacturing, ensure reliable supply, and ultimately deliver measurable cost savings compared to silicon carbide (SiC) filters.
 

Now manufacturing processes had to be defined and put in place. High volume filter plugging and metrology presented challenges, but Corning’s manufacturing teams demonstrated a steep learning curve, adapting quickly to meet the new requirements.

The official launch of Corning® DuraTrap® AT filters in 2005, laid the foundation for further advancements in diesel emissions control technology. In the following years, Corning even adapted the technology for heavy duty applications. To support ongoing product development and validation, Corning established its own vehicle testing fleet, generating on-road data that demonstrated enhanced performance for AT filters and next-generation DPFs.
 

Later product generations, like Corning® DuraTrap® AT HP filters, which allowed for optimum SCR catalyst loadings, offering high filtration efficiency, good NOx performance and low pressure drop brought the right product attributes to convince more OEMs.
 

Corning continues to expand its reach to niche markets. For example, the development of AT partial filters for India’s 3-wheeler market (0.4l diesel engines) addresses unique regional challenges. This innovative solution earned Corning the "Environmental Technology of the Year" award in 2017 and continues to see strong adoption as India tightens emissions regulations.
 

Reflecting on 20 years of DPF innovation, Lutz Kercher, DVP & Commercial Director, Corning Environmental Technologies, shares: “None of this success would have been possible without the incredible teamwork, expertise, and adaptability of our people across R&D, manufacturing, and sales. Corning’s unwavering commitment to innovation and collaboration has driven decades of progress, enabling us to tackle complex challenges, meet diverse customer needs, and ultimately make a lasting impact on the air we breathe. The teamwork demonstrated, is a testament to what can be achieved when talent and determination unite behind a shared vision.”

 

> Read the second article of this series: Corning recounts being on the cusp of DPF innovation

> Read the first article of this series: 20 years of Corning® DuraTrap® Diesel Particulate Filters: Innovation that powers cleaner air

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