Bringing the Future Faster Through Innovation and Analysis, by American Axle & Manufacturing (AAM)

AAM has been providing mechanical drivelines to automotive customers for more than 25 years. As the automobile transitions to electrification, so too must the driveline. AAM has developed a suite of innovative, lightweight, compact and cost-optimized electric drive units and electric beam axles to meet the growing global technology demand as electric vehicles continue to expand over the next decade. Engineering simulation, optimization and validation tools were significant enablers to increase the validation confidence and reduce the time to market for these new products.

Future.Industry 2021

Real-time Design Modification and Optimization with Altair Inspire

Inspire’s new parametric modeling allows you to capture the evolution of your model’s shape by showing the linear sequence in which the geometry was created. You can roll the model backward or forward, as well as group, delete, insert, suppress, or edit entities in the History Browser. Inspire also features a new and improved sketching interface and several new sketching tools. See how you can use these new tools to seamlessly add, remove, and parameterize features in your model and then use the Variables table to quickly make design updates and see how they affect performance is in seconds to minutes.

Future.Industry 2021

From Product Feasibility to Process Optimization for Metal Forming: Inspire Form

Product engineers are under constant pressure to reduce costs, improve quality and increase the throughput of manufacturing processes. Applying a simulation-driven design for manufacturing (SDfM) approach to product development can help understanding the product manufacturability early in the design cycle, while considering various design alternatives and choosing the best performing, manufacturable design up front. After a brief introduction of the metal forming process, the presentation will explore a typical use case of a sheet metal part - subject to static and dynamic loading – showing how simulation can be very effective in reducing cost for parts redesign and dies modifications, while providing engineers with valuable insights on the manufacturing process and product performance.

Future.Industry 2021

Panel Discussion: Trends in Design and Manufacturing Simulations

The goal for any design, structural and manufacturing simulation is to predict and fix defects early in the product development. This panel will discuss how design and simulation tools are helping engineers to be efficient. Experts will share their thoughts on current and future trends in manufacturing, focusing on how designs evolve using manufacturing simulations.  

Future.Industry 2021

Better Product Decisions Earlier with Simulation-driven Design

Altair® Inspire™ democratizes modeling and simulation making it accessible to all designers and engineers, particularly if they don’t have time for (or access to) traditional CAD tools. It now provides a robust history-based CAD modeling approach to create and modify geometry easily and quickly.

Getting Started

Using Integrated Simulation to Optimize Heavy Equipment Design

Heavy equipment manufacturers want to design products that are durable and perform at their peak under a variety of conditions. To accomplish this, Altair provides an integrated multi-disciplinary simulation environment to virtually test and optimize equipment performance and therefore, help reduce design and development costs. Using simulation-driven design, studying the full dynamics of a product or system is possible, from motion analysis to complete lifecycle durability testing.

Technical Papers

What is Simulation Doing for Machine Builders

A key development goal of any machine-building project is to produce perfectly running, reliable machines that make high-quality products. By leveraging accurate virtual prototypes, seamless production can be ensured earlier in the development process to help assess and improve product profitability.

Technical Papers

Fly High with Optimization - Optimizing Camcopter® S-100 Design at Schiebel

Unmanned aerial systems (UAS) are a rapidly evolving technology and used for a variety of civil and military purposes. To ensure airworthiness, UAS manufacturers rely on advanced simulation and manufacturing techniques to create efficient designs. Aerial systems active throughout Europe and operating with diverse payloads for different missions require a reliable vehicle architecture and fuel supply. To ensure perfectly tuned architecture and a lightweight design while increasing stiffness and strength, Schiebel used Altair solutions in combination with 3D printing. The engineers performed various simulations to optimize the design of AM engine parts. Using Altair’s topology optimization structural design tool, Schiebel reduced the weight significantly while maintaining high stiffness. Subsequently, the system was evaluated by laminar and turbulent flow simulation as well as conjugate heat transfer simulation using Altair CFD™. Contacts, NLFE and complex dynamic systems were modeled with Altair® MotionView® and Altair® MotionSolve®. Schiebel also took advantage of APA solutions.

Customer Stories

Gaining a Competitive Advantage with Rapid Design Exploration Technologies

Formula Student is an international motorsport engineering competition where teams from around the world design, build and then compete a formula style racing car. In this presentation, Team Bath Racing discusses how they make use of Altair Inspire for topology optimization and how it enables rapid design iterations.

Presented at the 2nd Altair Academic Outreach Event in June 2021

Speaker: Conor Smith, Outboard Suspension Designer, Team Bath Racing
Duration: 18 minutes


The Sound of Silence - Acoustic Analysis of a Rail Carriage Bellow using Product Alphacell

Noise reduction is an important issue when developing products and components for railway applications. Recently, Ultimate Europe had to perform an acoustic analysis of a rail carriage bellow. In addition to its own broad portfolio of simulation solutions, Altair offers a wide selection of complementary software tools through the Altair Partner Alliance (APA). With Altair’s unique, flexible licensing model customers have access to these solutions at no additional costs. Altair Units allowed Ultimate to leverage APA products and access the functionalities of AlphaCell to predict the acoustic response of the bellow. Results included reduced run time, a decrease in model set up time, and increased combined metric correlation.

Customer Stories

Altair Inspire - Rapid Design Changes with the Speed and Accuracy of SimSolid

Altair Inspire now integrates Altair SimSolid for fast, accurate structural analysis of complex assemblies, as independently validated by NAFEMS. In this short demonstration we'll show how to analyze the structural performance of an agricultural seeder, applying geometry modifications in seconds.

Use Cases

Optimizing Process Design at Renault - Faster and Easier Rim Optimization using Altair Inspire and HPC

As the traditional optimization process at Renault required many iterations, simulation engineer involvement, and a considerable amount of time, the company was looking for tools and methods to improve this process. They wanted to implement a new, easy-to-use simulation tool that would allow non-experts, part-time analysts, and designers to gain insight and accurate results in early design phases of Renault chassis projects. With the goal to enable designers to run simulation by themselves without being dependent on the engineer’s calculations, the team began using Altair Inspire. The implementation on the Altair HPC platform enabled the engineers to send their highly complex calculations to the HPC server while running calculations on their workstation. The results included time savings, an 80% increase in process automation and mass reduction up to 20%.

Customer Stories

Better Press Tools with Additive Manufacturing - Innovative Design, Less Material and Guaranteed Successful Manufacture

Etteplan offers engineering solutions to the world’s leading manufacturing companies for industrial equipment and plant engineering. Etteplan’s client Wärtsilä were looking to redesign their valve spring press tools used for mounting cylinder head valves. Altair OptiStruct™ and Altair Inspire™ were used to run topology optimization and finite element analyses to create design concepts, and Additive Works’ Amphyon software simulated the print process. This resulted in Etteplan’s additive manufacturing press tool design being ready to be printed within one week from when the project starting data was frozen.

Customer Stories

Optimizing Investment Casted Parts with Simulation and 3D-Printing

Investment casting is a valued manufacturing process known for its ability to produce detailed components with accuracy, repeatability, and in a variety of different metals, waxes, and high-performance alloys. Producing high-quality casted components is less prone to common design errors when a simulation-driven approach is used, leading to easier, more accurate analysis and optimization during the design phase.

Technical Papers

Manufacturing Process Simulation The Right Model for the Right Decission at the Right Time

Brett Chouinard, President and COO of Altair discusses Development challenges in Industrial machinery and illustrates how Altair's scalable simulation solutions provide the environment for simulation-driven innovation and how machine learning expands the capabilities furter.

ATCx Industrial Machinery 2021

Faster evaluation of real-world machines -  Improve system understanding with dynamic motion analysis

Daniel Jauss, Application Engineer CAE, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how to improve system understanding with dynamic motion analysis to Identify real behavior of the machine assembly and Identify peak loads.

ATCx Industrial Machinery 2021

Faster evaluation of real-world machines - Accurate structural assessment with real loading conditions

Felix Koerfer, Technical Consultant at Altair, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how accurate structural assessment with real loading conditions allows assessment of global stress and deformations, evaluation of bolt forces, and how accuracy & deformation of linear bearings cna be achieved.

ATCx Industrial Machinery 2021

Faster evaluation of real-world machines - Improve the Design with Studies and Design Exploration

Simon Zwingert, Technical Consultant, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how, to improve the design with studies and the design exploration on the complete assembly to perform weld line optimization.

ATCx Industrial Machinery 2021

Faster evaluation of real-world machines - Vibration Reduction with topology optimization

Daniel Jauss, Application Engineer CAE, gives a Demo Sessions on Altair Simulation Solutions for faster evaluation of real-world machines, explaining how to realize vibration reduction with topology optimization performing a modal analysis & Optimization of a machine portal, identifies economic manufacturing alternatives, and conducts a topology optimization for sheet metal constructions.

ATCx Industrial Machinery 2021

Simulation along product life cycle – The future is now From motivation to customer value

Industry expert Dennis Baum presents how Weber Maschinenbau applies simulation, how simulation can be used along product lifecycle and which benefits arise to customers and internal processes.

ATCx Industrial Machinery 2021

The Digital Approach to Industrial Machinery Design

The need to design more complex industrial machinery on shorter timelines means that companies ask engineers to do more with far less. Chad Jackson, CEO of Lifecycle Insights, describes the digital approach to industrial machinery design and explains strategies leveraging Simulation, Data Science and High-Performance Computing. He shows how companies creating equipment that increases cycle speed and improves yields in this technical report. The E-Book covers the following topics: - THE DEVELOPMENT CHALLENGE OF INDUSTRIAL MACHINERY - ADDRESSING STRUCTURAL STRESS AND STIFFNESS - ARCHITECTING AND VALIDATING SYSTEMS DESIGN - SELECTING THE RIGHT ACTUATION COMPONENTS - MITIGATING VIBRATION AND EXCITATION - PLANNING AND VALIDATING CONTROLS DESIGN - STREAMLINING COMMISSIONING - MONITORING THROUGH FIELD DATA - RECAP AND CONCLUSIONS


Mass Optimization of a 3D Printed, Small Series Prototype e-Drive Housing at Porsche

In his presentation, Sebastian Wachter of Porsche takes us through an exciting project where topology optimisation technologies were combined with 3D printing to create a highly innovative engine-gearbox housing that is 10% lighter than the existing component and twice as stiff.


The Culmination of 30 Years' Investment in Productivity Tools

Altair CTO James Dagg presents an overview of the journey Altair took to develop the leading modeling and visualization technologies we have today, and provides a look at what’s coming next to help you reduce your product delivery time. James Dagg has been at Altair for more than 30 years and is a visionary behind Altair’s software strategy and development activities. He has also led the development of Altair’s concept design technologies and oversaw the development of Altair’s CAE software suite for more than a decade.


A Firm Grip on Lightweight Design - optimized components and massive savings thanks to Altair Inspire

Würth Industrie Service GmbH & Co. KG (WIS) is an independent subsidiary of the Würth Group, providing integrated logistics solutions for automated, efficient supply of production materials as well as auxiliary and operating materials. The company offers individually tailored, logistical supply and service concepts such as scanner-supported rack systems and automated electronic ordering systems. In line with the company’s ultimate goals including innovation, cost reduction, and process optimization, WIS wanted to explore how simulation can be used to improve its products. As achieving a lightweight design was one of its main goals, the company started a collaboration project with Altair to perform topology optimizations on components of its KUKA robots. The project resulted in weight savings of 87%, leading to a reduction of repair costs by 94% and for used LED strips by 50%.

Customer Stories

Guide to Consumer Electronics Design and Packaging

To get a beautifully designed electronic product safely delivered to your customer, the work must start at the product design phase. Leveraging simulation-driven design, manufacturers are gaining greater insight and control over the development of innovative products, consistent manufacturing processes, and cost-effective, sustainable packaging.


Boosting U.S. Army Vehicle Payloads - Altair enables dramatic reductions in component weight for the GVSC

Payload is a key performance measure for military vehicles, determining how many personnel and/or goods can be carried. Reflecting this, the US Army Ground Vehicle Systems Center (GVSC) is engaged in a project to reduce the curb weight of vehicles, and thereby boost payloads, by redesigning and replacing existing components with lighter alternatives. Specifically, GVSC is combining topology optimization with additive manufacturing to realize significant weight savings, without compromising other critical requirements. Altair was contracted for external expertise to create new component designs. The results included achievement of 67% mass reduction for an alternator bracket, and cheaper costs than the current machined baseline.

Customer Stories

Altair Inspire Optimization Workflow

This series of videos shows users how to use Altair Inspire from start to finish. Examples include defining the design space, analyzing dynamic motion, conducting topology optimization studies, designing for additive manufacturing, verifying designs, and configuring assemblies.


Guide to Electronic System Development

Manufacturers today are tasked with designing smart, connected products at a breakneck pace to stay ahead of the competition. As performance demands continually increase, packaging sizes become smaller, and device connectivity becomes more critical, schematic engineers and product designers need ways to make efficient design decisions and collaborate with one another to optimize complex interconnected mechanical and electromagnetic systems. To develop the next generation of smart products, organizations are turning simulation to improve device performance and drive profitability.


Topology Optimization Study in Altair Inspire

Inspire offers a number of topology options including: optimization objectives, stress and displacement constraints, acceleration, gravity, and temperature loading conditions.

Use Cases

Dynamic Motion Analysis in Altair Inspire

Easily generate dynamic motion of complex mechanisms, automatically identifying contacts, joints, springs, and dampers.


Geometry Creation and Simplification in Altair Inspire

Create, modify, and de-feature solid models using Inspire's modeling tools. Leverage the speed and accuracy of SimSolid to evaluate multiple variants.

Use Cases

Guide to Process Manufacturing

Any industry that produces bulk quantities of goods such as pharmaceuticals, food, chemicals, or cosmetics, is seeking to produce these products consistently while reducing cost factors like waste and down time. Due to the nature of process manufacturing, multiple ingredients are combined to be mixed, coated, or sorted, so understanding the behavior of these processes is of paramount importance for manufacturers. Through the use of simulation modeling and Smart Manufacturing principals, manufacturers are now able to optimize these processes, leading to greater productivity and profitability.


Sustainable Design-to-Part Workflow for Additive Manufacturing of Lightweight Components Using Amphyon & Altair Inspire™

Advancements in 3D printing and design optimization for additive manufacturing (AM) is changing the industry’s overall approach to product design. This webinar features Altair Inspire™ a solution for designing parts through additive manufacturing and Amphyon, a complementary partner tool available through the Altair Partner Alliance. Through a combined workflow we’ll demonstrate an alternate and more efficient approach towards generative design. Instead of manufacturing the part, a process simulation in Amphyon is conducted to predict the impact of the AM process to the design. This feedback is then used to optimize design further and improve the manufacturing process by essentially fixing the defects early in the design process.


Topology Optimization Improves Gondola Lift Station Building

In modern passenger transport systems, flawless operation, comfort, and safety are key engineering criteria for design. To guarantee these key performance indicators, demanding fatigue tests are performed to ensure a component’s performance and strength. Advanced simulation methods can help to achieve an optimal design and ensure that components meet even the highest safety requirements. Using Altair Inspire, Doppelmayr, a manufacturer of ropeways and innovative transportation systems for ski areas and urban areas, built a design that passed the safety test, and optimized the gondola station to be lighter, safer, and more durable than requested. More recently, Doppelmayr also started using Altair SimSolid™ to explore its designs and create structural efficient concepts for large models and complex assemblies.

Customer Stories

Verify Final Designs in Altair Inspire

Investigate linear static and normal modes analysis on a model and visualize displacement, factor of safety, percent of yield, tension and compression, von Mises stress, and major principal stress.


Altair 2020 Mechanical Online Meet-Up #2 :אופטימיזציה טופולוגית – שלב ראשון בתכן

המיט-אפ מקוון עם המומחים בתחומי האופטימיזציה הטופולוגית התקיים ביום רביעי 25 לנובמבר. רוב עלות המוצר נקבעת בשלבים הראשונים של התכן; הבעיה שבשלבים אלו הידע על התנהגות החלק במוצר היא בסיסית, ובמיוחד אופן השתלבותו הפונקציונלי. השימוש באופטימיזציה טופולוגית מספקת למתכנן בין-היתר כלי איכותי המאפשר לבצע את התכן על בסיס נקודת העבודה האופטימלית. האופטימיזציה הטופולוגית תורמת להבנת התנהגות החלק במצבים שהאינטואיציה ואפילו הניסיון ההנדסי איננו יכולה לחזות. השימוש באופטימיזציה הטופולוגית חוסך סבבי תכן ומאפשרת לבחון/לבחור את טכנולוגיית הייצור. אם בתכן 'מסורתי' המתכנן יוצר את גיאומטריית המבנה ובודק עמידה בדרישות בתכן, בתכן מבוסס אופטימיזציה טופולוגית המתכנן מגדיר את האילוצים והיעדים ומקבל את המבנה האופטימלי. מסתבר שהשקעה של זמן מועט בביצוע האופטימיזציה הטופולוגית בשלב הראשוני של התכן חוסכת זמן וכסף רב. האופטימיזציה משמשת דה-פאקטו כ'מכונת קונספטים' עוד לפני תחילת ביצוע התכן. ההרצאה תסקור ותדגים את השימוש בגישה בתהליכי הפיתוח ברפאל באמצעות תוכנת INSPIRE .


Certified Panorama Thanks to Simulation

When planning offices and foyers to showcase the hallmark values of their customers, many architects benefit from the open and inviting atmosphere of glass structures. Faraone, designer and manufacturer of such lightweight structures, used Altair solutions to analyze and redesign support structures for large-scale glass elements, which are the core business of the company. The results are topologically optimized and stiffer aluminum channels that can host the structural glass element. With cost reduction, shorter development times, and design efficiency, this use case from Faraone demonstrates the benefits of simulation technologies in accelerating product development.

Customer Stories

Inspire Introduction 2020

In this course, you will have the opportunity to learn about the Inspire 2020 interface along with tools and workflows contained within Inspire. Modules contained within the course provide detailed descriptions of the tools and workflows within Inspire. You will also have the opportunity to watch and perform hands-on exercises within each module.


Explore Design Options and Streamline Manufacturability Using Altair Manufacturing Platform

Designing consumer electronics for mass production requires a team of experts focusing on various aspects of design and manufacturing process. With a fragmented engineering process, exchange of models and information can cost valuable time in a competitive landscape. This webinar presents Altair’s unique Simulation Driven Design platform will shorten your design cycle, time which is pivotal to a company’s success.


Digital Twin Design Process for Efficient Development and Operation of a Customized Robot

In a joint project MX3D, ABB, and Altair demonstrated how a 3D printed robot can be improved by using a digital twin process to achieve more precise positioning.

White Papers

Applying large-scale 3D Printing and Digital Twin technologies to the factory floor

ABB, MX3D, and Altair demonstrate how Industry 4.0 will deliver customized manufacturing equipment.


Connect designer with CAE expert - efficient collaboration, true consistent environment

Altair Expert CAE platform includes high end CAE tools for CAE experts to any simulation, computational fluid dynamics (CFD), finite element analysis (FEA) or electromagnetics are only a few examples which needs your business might have. In this webinar, you learnt how Altair linked the two different worlds of designers and CAE specialists in a smart way within the same intuitive easy GUI on the same database. Both worlds can work on the same database with no need to do work twice or lose information in the development process.


Guide to Additive Manufacturing for Medical

Additive manufacturing offers the medical community exciting opportunities to reduce cost and logistical hurdles while improving patient outcomes. Huge leaps in additive manufacturing innovation have been enabled by simulation-driven design. In this guide, we will explore the use of simulation and analysis technology in the medical field to design complex AM solutions, explore material decisions, optimize structures for performance, and ensure that designs can be printed efficiently.


Finetuning performance and manufacturing feasibility

Altair Inspire is an easy-to-use rapid simulation solution for design engineers. It enhances the concept development process by enabling simulation-driven design to increase your product’s efficiency, strength and manufacturability. In this webinar, we showed how Altair Inspire Polynurb Technology had been used to redesign optimized structures inuitive and fast. The geometry had been used for notch stress optimization before the we see how the manufacturability will be validated for a 3D printer and casting design.


Topology optimization considering manufacturing realities

Altair Inspire Topology Optimization is the world's leading tool for topology optimization, including advanced manufacturing constraints to create production-ready solutions to real-world challenges. In this webinar, we showed how Altair Inspire Optimization technologies provides the foundation on which our customers are able to develop with an easy and intuitive toolchain completely new ways to solve their daily challenges. In terms of component design and manufacturing processes.


Holistic system simulation with MBD and FEM: efficient load identification ensures structural integrity

Altair Inspire Motion is a dedicated multi-body dynamics (MBD) tool with a robust contact algorithm. It is capable of handling systems with large degrees of freedom and offers a reliable and fast solution. In this webinar, we showed how Altair Inspire Motion had been used to determine loads in the system and is seamlessly coupled with other Altair modeling tools like Altair Inspire Structure and Altair Activate for control simulation to create dynamic motion analyses of complex mechanisms and use these dynamic loads as load cases for optimization.


Using Altair Software for Simulation-driven Design

The widespread adoption of Altair SimSolid™ has enabled customers to accurately test more ideas during each design iteration. Altair Inspire™ was the first tool to democratize topology optimization. Altair Inspire now embeds the speed and accuracy of SimSolid supporting faster, easier design exploration and product creation for allowing design engineers, product designers, and architects to create and investigate structurally efficient concepts for complex assemblies.

Use Cases

Using Altair Software for Manufacturing

Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes. Users can validate designs early in the manufacturing process with the simplicity and affordability of the simulation software, as well as use optimization technology with specific manufacturing constraints to design better, more efficient products.

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Use Cases