The Digital Approach to Industrial Machinery Design

Chad Jackson, CEO of Lifecycle Insights, describes the digital approach to industrial machinery design and explains strategies how companies creating equipment that increases cycle speed and improves yields in this technical report.

Technical Papers

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.

Presentations

The Culmination of 30 Years' Investment in Productivity Tools

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 overawe the development of Altair’s CAE software suite for more than a decade. Today, James is going to give an overview of the journey Altair took to develop the leading modelling and visualisation technologies we have today, as well as providing a look at what’s coming next to help you reduce your product delivery time.

Presentations

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.

Brochures

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

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.

Brochures

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.

Brochures

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.

Webinars

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

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 .

Webinars

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.

eLearning

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.

Webinars

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.

Webinars

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.

Brochures

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.

Learn more at altair.com/manufacturing-applications.

Use Cases

SimSolid Simulation at the Speed of Design

Simulation has its greatest impact when done early and often in the design process. Now, SimSolid is reimagining how simulation-driven design is performed.

Presentations

Altair Inspire - Unit Cell Lattice Generation

Altair Inspire includes the ability to generate lightweight, unit cell lattice structures for 3D printing. Unit cells can easily be edited, evaluating the structural performance of different design variants in moments.

Use Cases

Driving Design from Concept to Manufacturing with Inspire

Altair Inspire has rapidly advanced from a topology optimization tool for designers to a design environment spanning industrial design, structural simulation and optimization, motion analysis and manufacturing simulation.

Presentations

Enhancing Product Design for Medical Devices

Medical devices of all kinds must be designed to withstand the structural and operational requirements associated with normal use, drop, and misuse, all while balancing weight and cost considerations. This webinar presents Altair’s workflow to enable simulation of structural, thermal, and fluid properties coupled with electromagnetics, and mechatronics in an integrated Multiphysics environment.

Webinars

Altair Inspire - Accelerate Simulation Driven Design

Altair Inspire is a tool that empowers you to create, explore, and study structurally efficient designs. This demo gives a brief overview of Inspire's motion, optimization, modeling, and analysis capabilities.

Use Cases

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

BOTTPOWER Designs Lightweight Bracket for Motorbike

BOTT stands for “Battle of the Twins,” a racing category for motorbikes with two-cylinder four stroke engines. Bottpower is a Spanish motorsport engineering company located in Valencia. They specialize in designing and building custom motorbikes for racing and street use. They design and build parts, systems, and prototypes for other companies. A project challenge at Bottpower was to design a lightweight stay bracket for their motorbike that could withstand the main and aerodynamic loads. The goal was finding the optimal weight and stiffness ratio to reduce weight while ensuring safety measures. All of this had to be done quickly in order to arrive on time at Addit3D, Spain's most important 3D-print fair, to showcase the bike. The optimal design for aerodynamic loads was found using Altair software.

Customer Stories

Altair for Industrial Design Applications

Altair’s industrial design tools allow designers, architects, and digital artists to create, evaluate, and visualize their vision faster than ever before.

Brochures

Altair for Structures Applications

Altair offers industry-leading engineering analysis and optimization tools from simulation-driven design concepts to detailed virtual product validation, and simplified modeling workflows to advanced high-fidelity model building.

Brochures

Altair Inspire – Altair SimSolid Analysis

Tips and Tricks You can now use SimSolid as your solver when running a structural analysis in Inspire. This gives you the ability to edit geometry, which was not possible in the stand-alone version of SimSolid, as well as yielding significantly faster results when running an analysis in Inspire. Linear static and normal modes analyses are supported when using the SimSolid solver, as well as all boundary conditions and results visualizations. SimSolid extends Inspire’s solver capacity and makes it much faster to analyze large assemblies and complex parts.

Tips & Tricks

Altair Inspire – Toolbelts

Tips and Tricks Inspire now has four toolbelts to help you quickly access the tools you need for geometry, structures, motion, and PolyNURBS. You can use the toolbelts with the default configuration of tools, or you can customize the toolbelts by adding and removing tools.

Tips & Tricks

Altair Inspire – Plot Manager

Tips and Tricks A new Plot Manager is now available which makes it easy for you to manually browse and plot motion results data, create cross plots (i.e. data vs. data), define pages in different layouts, and save the plots you've defined as a template for reuse.

Tips & Tricks

Altair Inspire – Pressure Mapping

Tips and Tricks Pressure Mapping: It is now possible to apply a non-uniform distributed pressure using an option in the Pressure tool’s micro dialog.

Tips & Tricks

Altair Inspire – Download Offline Help

Tips and Tricks You can now download and install an offline help package from within the product by selecting File > Help > Download Offline Help.

Tips & Tricks

Additive Manufacturing for Production

The Additive Manufacturing for Production survey conducted by TCT Magazine in association with Altair set out to understand the community’s desire and readiness for the much-promised land of series production using additive technologies. This collaboration between TCT and Altair was designed to understand the needs of the community in terms of current production capabilities, rate-limiting steps and areas of the technology that they believe needs improvement.

Technical Papers

Training - Mechanism Design & Analysis Using Inspire

With Altair Inspire Motion we can link components of a mechanism together using various types of joints and contacts to simulate the real-world connections in an assembly.

Webinars

Simulation-Driven Design for Additive Manufacturing

This webinar will take you through the concept and roadmap phase, all the way to the manufacturing process - all within Altair Inspire and Inspire Print 3D, a revolutionary generative design and 3D printing simulation environment that solves real world production challenges. Learn how to rapidly visualize production defects, rectify problems to avoid downstream production issues, save product weight, reduce material consumption and cost all through the use of intelligent complementary design technologies.

Webinars

Renault Nissan Mitsubishi Alliance Uses Altair SimSolid to Bring Vehicles Chassis Faster onto the Road

Renault Nissan Mitsubishi Alliance is a French-Japanese strategic partnership between the automobile manufacturers Renault (based in France), Nissan (based in Japan) and Mitsubishi Motors (based in Japan). Today, the automotive group has 122 manufacturing plants worldwide with nearly 450,000 employees controlling ten major brands: Renault, Nissan, Mitsubishi, Infiniti, Renault Samsung, Dacia, Alpine, Datsun, Venucia, and Lada. The ambition of the alliance is to offer autonomous drive, connectivity features, and services on a wide range of affordable vehicles. As part of the Renault Chassis Le Mans plant, which is building car-to-ground connecting components for the Renault Group and for the Alliance, the CTC Chassis Technical Center is a CAD engineering center where 350 engineers and technicians are working with a focus on testing and validation. Renault has been using SimSolid to perform simulations to develop lighter chassis faster.

Customer Stories

Taking Off with Simulation

New airborne solutions are being developed to accommodate one or more persons for air travel. Explorations including large drones, small helicopters, airplanes, and flying cars will enable companies to respond to the demand for Personal Air Mobility (PAM). The team at Talaria was founded by students at the Delft University of Technology. The idea for Talaria’s Individual Air Mobility project began at the end of 2017. Founder Philipp Essle heard about the Boeing GoFly competition which rewarded the best designs for a one-person aircraft. Talaria’s mission is to develop an electrically driven PAM that can take-off and land vertically in urban environments. Talaria is using Altair Inspire to check whether material and weight could be reduced through topology optimization. This approach resulted in a significant 1.5-kilogram weight reduction of the rotor hubs.

Customer Stories

Inspire 2019 Introduction

In this course, you will have the opportunity to learn about the Inspire 2019 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.

eLearning

Engineer's Guide to Developing an Additive Manufacturing Strategy

This guide walks you through the decision-making process of taking additive manufacturing to production, answering some of the most important questions related to taking additive manufacturing to production

White Papers

Generative Design Gallery

Watch the video to learn how Altair enables designs for production, moving additive manufacturing from an advanced capability to a production capacity with the power of simulation.

Videos

Development of A new vehicle front sub-frame using Altair Inspire topology optimization

Presentation by Edan Lazerson, CAE Engineer, Plasan. The Stormrider is a new vehicle which was designed from scratch and developed by Plasan. Altair Inspire was used for Topology optimization In order to find the ""best"" design for the vehicle front sub frame. The available volume (design space), 5 different load cases and target mass were specified and the optimization software calculated geometry to maximize stiffness. The optimization results were complex to manufacture with traditional technologies; the simulation and design teams collaborated on designing a manufacturable front sub frame assembly. The new design was simulated to ensure it will withstand all the required loads. The front sub frame was implemented and tested on the prototype vehicle. The optimized front sub frame proved mechanically sound, while satisfying the mass and geometrical requirements. The early stage optimization reduced the development time, by creating a valid geometry however, the topology to manufacturable design process is not trivial. In this presentation, we will present the mentioned development stages and compare the test results to the simulation predictions. Presentation at the ATCx in Israel, Netanya on October 30, 2019.

ATC Presentations

The C123 Process - A Rapid Simulation Process to Optimise the Weight & Performance Attributes of a BIW Structure

Dr. Stuart Bates, Concept Technical Specialist at Altair presents at the UK e-Mobility seminar 2019. Rapid Exploration of Packaging Alternatives e.g. Battery System Layout, Battery Frame / BIW Integration. Developing Balance Design (Weight vs Attribute Performance), Target Setting using Simulation.

Presentations, Videos

Altair Inspire – Joint Coupler

Rotational and/or translational movements of connected parts in your motion model can now be coupled together with the Couplers tool.

Tips & Tricks

Altair Inspire –Top Bottom Mid Surface Extraction

Top bottom mid surface extraction in Altair Inspire.

Tips & Tricks

Transformative Flight Transportation: Challenges Become Opportunities

Advances in energy storage, motor efficiency, and flight control systems have us on the potential cusp of a revolution in air mobility. This comes at a time when many traditional transportation infrastructures are saturated and new modes of mobility are desperately needed. The presentation will provide an overview of recent developments in urban- and extended-air-mobility and discuss the hurdles that must be overcome, not only technical obstacles but also challenges in regulations, societal acceptance, and business. It will provide context with an overview of our own technical challenges and successes, from the imminent Transition® to the aspirational TF-X.

ATC Presentations

Human Plus Machine: How Sarcos is Revolutionizing the Future of Work with Industrial Robotics

With the prospect of increasing labor shortages among a wide variety of industries, combined with the significant costs of occupational injuries and the ever-increasing pressure to increase productivity, leading robotics company, Sarcos is in a unique position to deploy industrial robotics designed to increase productivity while eliminating injuries, by augmenting rather than replacing human workers. Chris Beaufait, COO of Sarcos, discusses the current robotics landscape, why automation is not the right solution to the problems industries are facing, how Sarcos and its product lineup - including the full body, fully powered Guardian XO exoskeleton - will play a critical role in defining the workforce of tomorrow, and his vision for the robotics industry over the next five to 10 years.

ATC Presentations

The Key Role of Simulation in Development of Aluminum Profiles and Study of Glass Structures in Shorter Design Time

This presentation discusses advancements of the range and quality of products in the last few years at Faraone, thanks to the adoption of both Altair Inspire and SimSolid. SimSolid is a great tool that allows Faraone to study and refine the design of complex structures and a variety of different products, not just glass balustrades. In less than half an hour, it makes it possible to analyze and verify a three-story glass staircase, directly from the 3D CAD file, a simulation that would normally requires about half a day. Additionally, Moreover the original CAD drawing does not need simplification, SimSolid® works directly from the 3D CAD file, allowing fewer issues, and a better, final solution.

ATC Presentations