Lightweight Design Structure, Organic Shapes, generative design, derived from topology optimization

Lightweighting

Applying simulation upfront in the product development process means you can meet your performance targets by designing lightweight earlier instead of working to take mass out later. We develop and implement intelligent simulation technologies that allow you to find the optimal balance between weight, performance, and cost for your products. Altair accelerates your lightweighting initiatives with topology optimization, advanced materials, and pioneering innovation.

CASE STUDY

Less Weight, More Freight

Customizable logistic solution realizes payload advantage of up to 4 tons reduced manufacturing complexity 40% less parts to assemble.

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Topology Optimization

Topology optimization develops optimized structures by considering design parameters like expected loads, available design space, material, and cost. Embedded early, it enables the creation of designs with minimal mass and maximal stiffness. For more than two decades, Altair OptiStruct™ is the original topology optimization structural design tool and has driven the design of products you see and use every day.

  • Right the First Time: Create optimal designs early and reduce costs associated with design failure.
  • Exceed Performance Targets: Maximize performance by starting with part and assembly designs that withstand all real-world conditions and loads.
  • Design for Manufacturability: Find the best material distribution for your traditional or advanced manufacturing process and compare designs.

Altair Inspire™ brings OptiStruct® into a new user experience encouraging earlier application of topology optimization. Both tools consider multiple manufacturing constraints, including symmetry patterns, draw direction, cavity avoidance, overhand angles, and extrusion. Topology optimization allows for fast design exploration, improved development productivity, and identifies opportunities for part consolidation.

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Advanced Materials

Altair provides comprehensive tools to design, optimize, and analyze parts and assemblies manufactured with laminate, chopped fiber, and particulate composites. OptiStruct is widely used for the design and optimization of laminate composites. It delivers optimal ply shapes, number of plies, and stacking sequence, while observing manufacturing constraints. Altair Multiscale Designer™ provides accurate and efficient simulation of materials and parts manufactured with continuous and chopped fibers, honeycomb cores, lattice structures, and more.

Generating and evaluating a finite-element analysis (FEA) model with composites adds another dimension to the pre- and post-processing requirements. The next generation of HyperWorks generates laminate definitions efficiently and visualizes the stacking sequence, ply orientation, and draping angle deviations on the FEA model. It maps geometry ply shapes to element sets and performs sophisticated post-processing at the laminate or ply level.

Composite material analysis can be carried out in OptiStruct for linear and non-linear structural problems under static, dynamic, and thermal loadings, and Altair Radioss™ for highly non-linear problems under dynamic loading. Altair tools model delamination, crack propagation, and fiber and matrix failure under real-world conditions. Without physical testing teams can assess the stiffness, strength, durability, and stability of a structure, in addition to understanding the impact performance of composite designs.

How can we help you to make your product lighter?

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Pioneering Innovation

The Altair product engineering services team works across industries in order to use processes and techniques from one industry and apply them to another. We've taken composite design techniques from the aerospace industry and applied them to passenger cars, and optimization processes from automotive and applied them to consumer goods. Our team creates industry-leading optimization solutions with our product development consultants to deliver the best possible technology application that other companies cannot match.

The team uses the latest optimization techniques and processes to deliver innovative solutions for our clients' product weight, performance, and cost challenges. In the traditional design process, simulation technology is used as a verification tool, and results can be delivered too late to impact the design direction. We believe in a different approach - CAD and CAE are deployed in parallel.

The concept phase of product development often fails to deliver mature engineering data to support the program business case, often resulting in costs to correct issues. Altair's process is used to rapidly interrogate design alternatives in the early development stage to help eliminate the risk of using immature concept deliverables and potential downstream issues in product development.

Explore Lightweight Design

Automotive’s Only Award Dedicated to Vehicle Lightweighting

We have a deep commitment to vehicle efficiency, so much so that we have established the automotive industry’s only award dedicated to vehicle lightweighting. The Altair Enlighten Award honors the greatest achievements in vehicle weight savings each year. It inspires interest from business leaders, engineers, policymakers, educators, students and the public, stirring competition for new ideas and providing an incentive to share advances.

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Featured Resources

Towards Efficient Composite Pressure Vessel Design

Competing future vehicle concepts have drives using clean energy stored in batteries or hydrogen. On-board storage of high-pressure hydrogen gas to supply fuel cells needs weight-efficient pressure vessels utilizing composite materials, that operate safely and reliably under challenging thermo-mechanical service conditions, be affordable and meet standards. Partnering with the Altair Composites Team, CIKONI identified the benefits of Altair Multiscale Designer™ to increase simulation efficiency by its virtual material characterization to create accurate and reliable material models for structural simulation. They applied Multiscale Designer, Altair OptiStruct and Altair ESAComp interfaced with a third-party filament winding simulation package to handle the simulation process.

Customer Stories

Form Follows Function - thyssenkrupp AG - Reinventing the Elevator Concept

thyssenkrupp Elevator AG has presented the MULTI concept, the world’s first rope-free elevator. The drive is ensured by a linear electromagnetic motor. To enable an economically feasible operation, it is necessary that the total weight of the lift does not exceed a certain limit. Designing the overall system of the MULTI lift according to this weight specification is one of the major challenge for thyssenkrupp Elevator.

In this presentation, an overview of the partnership between thyssenkrupp Elevator and Altair, the chosen design partner since the early phase of development, will be introduced. Thereby, different aspects of the simulation driven design process will be highlighted, taking into account several tools throughout diverse stages of the development cycle.

ATC Presentations, Videos

Design Lightweight and Efficient Stamping Dies with Topology Optimization

Ford Otosan in Turkey designs big stamping dies with the help of topology optimization using OptiStruct. Weight savings of 20% were possible on their first attempt to try optimization on a new stamping part.

Video Testimonials

Reduction of Moving Masses – Streamlined Design for Improved Engine Performance

To expand the rpm range of a motorcycle engine, a new type of rocker arm with lower inertia was needed at KTM. The new rocker arm was required to have the same, or better stiffness and deformation level as the previous design. KTM used Altair HyperWorks™ for nonlinear topology optimization and nonlinear structural analysis to develop the new rocker arm. Thanks to this, the component inertia could be reduced by 15 percent, component mass was reduced by 21 percent, and the stiffness increased by 14 percent which lead to an extension of the rotational speed by 150-200 rpm.

Customer Stories
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