Wisconsin Precision Casting Corporation, an investment casting manufacturer utilized Altair Inspire and Altair Click2Cast for a design study that focused on the redesign of a regenerative turbine pump cover.
Cyclone Racing utilized topology optimization and generative design to decrease the mass of its FSAE vehicle by generating a new design concept for its wing mount achieving 67% weight reduction of the bracket.
IAI and SpaceIL utilized topology optimization with 3D modeling and rendering to design a 3D Printed thruster bracket to be used on its Google Lunar XPRIZE craft for its trip to the moon.
A university team at MIT, Pune used topology optimization and additive manufacturing to develop two new designs for the Quad-rotor UAV drone that were lighter and stronger than previous designs.
U-Shin is currently employing Altair Click2Cast to perform testing and optimization to create sound, redesigned automotive parts.U-Shin has seen significant time and cost savings by utilizing Altair Click2Cast.
Ryerson's International Hyperloop Team utilized finite element analysis and topology optimization to redesign a metal additive manufactured motor bracket. PolyNURBS was used to make the design 3D print-friendly.
Ankers performed co-simulation using a combined multibody and brake systems model in MotionView and Activate to generate more accurate results to analyze thermal and other effects on braking.
PaceControls developed its 3rd generation Android-based HVACR Equipment control, which satisfied all project requirements and had 0 defect escapes, by implementing a Model Based Design (MBD) process.
Woodland/Alloy Casting is simulating and testing aluminum casting projects in Altair Click2Cast. By running simulations in Altair Click2Cast, Woodland/Alloy Casting can more accurately predict defect-free castings, while reducing time and cost in the overall casting process.
Faraone accelerates the design approach for lighter and stiffer architectural components with premium topology optimization technology.
APEL Extrusions employs die extrusion simulation software to test die extrusion performance. This allows APEL to greatly speed up the design process and test multiple simulations per week.
Philips uses modeling software to quickly and easily visualize design concepts so design and engineering colleagues can work hand-in-hand throughout the process, and ultimately conceptualize final products.
Alstom coupled topology optimization with additive manufacturing to explore the feasibility of alternate manufacturing to traditional casting. This resulted in a 70% weight reduction of its locomotive component.
LEIBER Group, which specializes in developing lightweight metal components, applied topology optimization to determine the ideal shape for a vehicle suspension beam, resulting in mass savings of over 50%
Triton Bikes utilized Altair Inspire to Increase performance, decrease the overall weight, and simplify manufacturability of a 3D printed custom bike rear yoke.
HYperWorks used by leading Indian manufacturer of seating systems Harita, for homologation testing, regulations and crash analysis for all commercial vehicle seats, bus passenger seats and tractor & off-road seats
Sintavia utilized Altair Inspire to prove the ability to additively manufacture optimized aerospace replacement parts that exceed existing part performance while decreasing
the overall weight.
Gator Motorsports utilized Inspire to redesign its brake pedal, as well as suspension bell cranks. This resulted in increased stiffness and a reduction of weight.
The Politecnico di Milano University implemented generative design software to quickly and easily identify the ideal shapes and materials for three architectural design concepts.
The team at Technische Universität Dresden used Altair Inspire to redesign a Formula Student steering column mount that saved 35% of the weight and is produced with additive manufacturing.
AMETEK utilized model-based development to develop a new embedded control system for a aerospace suit chiller unit under a very tight schedule and high safety standards.
Using Altair Embed, Texas Instruments was able to develop an embedded simulation of an entire system.
Robot Bike Co. designs and manufactures fully customizable 3D printed carbon fiber mountain bike frames. Finite element analysis was used to determine loading conditions and optimize for additive manufacturing.
The effects of obesity on occupant responses
in frontal collisions were investigated using
the UMTRI whole-body human finite element
models. A modeling approach was developed
and applied that allowed for rapid change of a
baseline human body model into geometries
representing adults with different BMIs without
the need for re-meshing the models.
3D Systems utilized topology optimization, finite element analysis, and generative design to conceptualize a new material layout for a 3D printed skateboard deck and trucks.
Award winning industrial designer Steve McGugan uses Altair Evolve to design and model a range of unique products.
Scania uses a simulation-driven design process including topology optimization and finite element analysis. This speeds up their design and development process and produces lighter, more efficient components.
American Axle & Manufacturing employed topology optimization and FEA to redesign an automotive carrier to achieve a weight reduction of 20%.
Dimensions Furniture incorporates industrial design and modeling software to design and render furniture products for presentation to buyers and direct handoff to manufacturing teams.
The Shanghai Arts and Crafts Factory utilizes digital NURBS-based conceptual design tools to generate ideal 2D and 3D designs and renderings for parade floats.
Studio-X and Tokyo DIGITAL use topology optimization to improve structural optimization and enhances building performance while reducing assembly time and material waste with lightweight design.
In this paper, several failure criteria are compared in their ability to predict necking point and failure propagation during a forming process. The paper has been presented at the 2014 IDDRG Conference in Paris, France.
Renishaw and Empire Cycles utilized generative design to conceptualize the world's first metal additive manufactured bicycle frame. This resulted in a 33% weight reduction of the bicycle.
HardMarque coupled topology optimization with additive manufacturing to conceptualize and refine the design of a piston. The final piston design is 23.5% lighter than the original design.
Race Face redesigned a bicycle crank using generative design and finite element analysis. The concept design process yielded a part with increased stiffness and strength without increasing the weight of the part.
Architect Peter Macapia aims to change perceptions of how buildings can look; generative design software aids in imaginative engineering and architecture projects, integrating design and testing in the same space.
Sundog Eyewear accelerates design times through the use of conceptual design softwarewhile improving visualization of the final product using integrated rendering.
M.TEC Engineering Continues to Benefit and Yield New Business Due to Advantages of the Altair Partner Alliance (APA)
HBPO GmbH optimizes their design process by utilizing multiple products, such as Moldex3D, Total Materia and MADYMO, alongside HyperWorks products for the development of their front end modules.
Isringhausen applies DesignLife, Moldex3D, and Total Materia alongside RADIOSS, OptiStruct and other HyperWorks tools to optimize weight and durability of their customized seats while still meeting safety standards.
Evenflo employs topology optimization and generative design simulation for “sustaining engineering” where fast turnaround is essential for functional improvements of infant car seats design.
Hollywood concept artist Ron Mendell converts sketches to fully rendered digital 3D models, incorporating real world materials, dimensions and constraints.
TokyoFlash is a world leader in the design and sales of unique watches. They use Altair Evolve to speed product development.
Pininfarina Extra blends the use of industrial design, modeling and topology optimization software to achieve the brand's values of elegance, essentiality and innovation outside of the automotive industry.
Automotive Lighting uses free-form modeling software to create concepts for customers in a fast and flexible way. Concepts are presented visually in daytime and nighttime conditions using photorealistic rendering.
Novellini applies industrial design and modeling software to set the pace of innovation for the manufacture of bathroom solutions and wellness products in Europe.
Bros Manifatture is a "superbrand" in the world of fashion jewelry and watches with over 200 new products each year.
XOX Audio Tools utilizes high design and advanced technologies to create cutting-edge musical instruments.
Korg utilized 3D modeling and rendering simulation to manage the frequent design modifications that occur during the product development process.
When the auto industry crashed in 2008
and the tool shop where Jay Weiner worked
closed its operations, he started his own
company, called BiggerBoat Solutions Ltd.
He carries out metal-forming simulations
for major tooling suppliers and originalequipment
manufacturers. With 15 years
of experience in tooling design, Weiner and
his Toronto-based practice offered a service
that no one else had perfected but that
was crucial to a key process in automotive
manufacturing: the simulation-based die
design for stamped sheet-metal parts.
Challenge: Define new process that includes accurate component data
Altair Solution: Use HyperForm and RADIOSS in development process
In 2008 PWO Germany (Progress-Werk Oberkirch AG) had to develop and produce a new steel made automotive cross car beam (CCB) for the dash board of a new car. PWO received the CAD model, the design space definition and other pre-defined standards of the component from the customer and developed and produced the fitting cross beam based on this information. PWO used the HyperWorks Suite to develop the component. HyperMesh was used to transfer the CAD model into a FEA model, which was then used to run dedicated analysis and simulation tasks. To fulfill the requirements for crash and modal analysis, the company used OptiStruct to optimize the component, RADIOSS and other external solver to run the calculations and HyperView for the post processing. HyperForm was used to check the production feasibility of the individual components and for metal forming simulation tasks. It was important for PWO to have a software suite available that could cover all simulation tasks within one graphical user interface and licensing system.
Using Altair HyperForm, Mark Auto was able to significantly improve the material utilization for their existing production dies. Mark Auto re-designed two existing dies for wheel arch an wheel housing and was able to dramatically reduce material scrap with minimum rework in their tools while not compromising on component quality.
HyperForm Improves Accuracy and Robustness of Tool Design and Manufacturing Process at Summit Auto Body (SAB)
Leveraging HyperForm’s sheet metal forming solution, SAB designed the validation process and press tool design covering the vital areas of virtual prototyping/testing, which, in turn, reduced the time-consuming manual process drastically.
Wagon Automotive, a system and module supplier of components to major car builders,
sought ways to accelerate product development and reduce prototyping costs while maintaining high quality.
Adopting the HyperWorks suite of advanced CAE tools enabled the company to achieve both those goals.
Wagon Automotive now uses HyperWorks during the entire development cycle, from concept design to optimization.
Using Altair HyperForm, HyperWorks’ stamping simulation technology, Godrej was able to design and
fine-tune a successful tool for a rear fender, while minimizing die testing time by reducing physical
trials. Leveraging numerical analysis, Godrej was also able to predict the size, shape and location of
the blank accurately. HyperForm’s ability to visualize failure in incremental simulation enabled them to
finalize the draw bead location and characteristics.
Using Altair HyperForm, India-based OMAX Autos was able to significantly reduce production
costs and maximize productivity by redesigning the manufacturing process for front housings.
Leveraging HyperForm’s simulation capabilities, OMAX Autos reduced the three-stage forming
process to a single-stage process.
Using Altair HyperForm, India’s Supreme Pressfab was able to predict the high nonlinear
material flow for fuel tank dies accurately. In doing so, Supreme was able to optimize the
blank as well as minimize die tryouts.
Using Altair HyperForm sheet metal forming simulation software solution, India based Mahindra & Mahindra was able to arrive at an optimum product (BIW Part) and tooling design. The Draw Shell was simulated using HyperForm to evaluate different tooling options.
Cut sheet metal forming time and costs through simulation-based techniques.
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