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Nonlinear Analysis Buyer's Guide
We created this guide to help managers of CAE budgets navigate the multifaceted decisions companies must make when choosing a nonlinear analysis software vendor. Additionally, we’ve compiled some tips and best practices for successfully managing these deployments to satisfy the needs of growing engineering
teams while extracting maximum return on investment.

Topology Optimisation of an Aerospace Part to be Produced by Additive Layer Manufacturing (ALM)
OptiStruct helped EADS achieve significant weight savings in the design of ALM (additive Layer Manufacturing) components.

Optimization and Manufacturing of Carbon Fiber-Reinforced Plastic Components at Manz AG
Dr. Martin Steyer talks about OptiStruct as essential part of their Fiber Patch Preforming Process.

A Vision of Tomorrow's Architechture: Designing the LAVA Bionic Tower
Exploring design variants with OptiStruct's FE-based topology optimization to generate a free-form exoskeleton structure

Scaling Up Your Nonlinear Analysis Solver Throughput with HyperWorks Unlimited
In this webinar, you'll learn about OptiStruct's nonlinear analysis performance at scale as well as Altair's powerful and cost-efficient solutions for on-premise or virtual compute clusters.

Implementing CAE into the Design Process for Composite Tennis Racquets at Wilson Sporting Goods
Wilson Labs, the innovation hub at Wilson Sporting Goods, leveraged OptiStruct and Altair ProductDesign for composites finite element analysis to reduce design cycle time and enhance product value.

Biberach University of Applied Science, Institute for Architecture and Urban Development
Create modern, functional, stiff, and light architectural designs. Altair OptiStruct used to create feasible designs

Sujan CooperStandard Achieves Lighweighting & Performance Targets with Altair
Sujan CooperStandard uses solidThinking Inspire, OptiStruct and HyperMesh to design a torsional vibration damper that meets NVH criteria, optimize bracket and various mount designs.

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APWorks Light Rider: Optimization Process
First 3D-printed Motorcycle by APWorks (Airbus Group) called Lightrider. Altair's software OptiStruct was used for inspiration of the organic structure of the motorcycle.

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SimLab Tutorials - Analysis 1D Pretension and Bearing Pressure
Define material and properties; define quickly 1D bolts with pretension; defining loads and constraints; define contacts; export solver deck; run a linear static analysis with OptiStruct; visualize entities

SimLab Tutorials - Topology Optimization with Manufacturing Constraints
Create RBE connectors; create LBC and load cases; define the design space for a topology optimization; define responses; create manufacturing constraints; set an optimization objective; run an optimization with OptiStruct

SimLab Tutorials - Topology Optimization with Pattern Constraints_Y Bracket
Create RBE connectors; work with specifications for loads and loadcases; set up a topology optimization including pattern constraints; run an optimization with OptiStruct; view and post-process optimization results

Honeywell Aerospace - Reducing the Weight of Aircraft Engines
Brian Cottrell, Chief of Structures at Honeywell Aerospace, discusses how Altair ProductDesign applied HyperWorks' optimization technology, OptiStruct, to minimize the weight of new aircraft engines.

Applying Optimization Technology to Drive Design of a 100-Meter Composite Wind Turbine Blade
This presentation demonstrates how numerical optimization can be applied using OptiStruct to aid in the design development of a 100-meter composite wind turbine blade.

Virtual Design and Testing of a Medical Autoinjector, Project Overview
Nolato specializes in polymer-based product design and manufacturing to virtually design a device to automatically inject medicines, such as insulin for diabetic patients. Within this presentation different aspects of the product design cycle are considered, including co-simulations of the device operation during the actual injection process, misuse in case of forceful bending or opening of the loading tray, and drop tests of the autoinjector. Based on Altair’s optimization technology, alternatives for the rib structure of the casing are investigated. To assure manufacturability, molding and assembly simulations are performed to identify and mitigate problems likely to occur throughout the process.

Simulation-Driven Design of a Portable Basketball Hoop System - Initial Steps
A simulation-driven design process is proven to generate improved, more robust and cost-effective designs within a shorter design cycle. Incorporating simulation and optimization early in the design cycle helps shape the concept designs so less iterations and rework is necessary as the design matures. This paper is intended to discuss the initial steps that can be taken when using a simulation-driven design approach to design and engineer products. Several of Altair’s design and engineering tools will be coupled to achieve various design goals.

eBook: Practical Aspects of Structural Optimization
This study guide aims to provide a basic introduction in the different optimization methods. Designed for users who are interested to learn more about the “inspiring” world of optimization.

Northwestern University Success Story
Using HyperWorks for Teaching Computational Optimization Methods in Engineering Design at Northwestern University

Luxon Engineering Applies Optimization-driven Design to Motocross Components
The motorcycles used in motocross racing demand light weight and high strength components in order to gain a performance advantage over the competition. In this video testimonial Billy Wight, President of Luxon Engineering, presents a case study of applying Altair HyperWorks optimization techniques in the design of a motocross triple clamp assembly and rear suspension linkage.

Combining topology optimization with laser additive manufacturing reveals new potential for lightweight structures
Challenge: Development of design and optimization methods to improve components made with laser additive manufacturing methods.

Altair Solution: HyperWorks, OptiStruct, Simulation Driven Design Process

Benefits: increased material efficiency, lighter and stiffer structures, less user training required, flexible and adaptable manufacturing process


Optimization Technology: Leveraging a Solid Foundation to Innovate Better Products
Steady improvements in the OptiStruct solver platform over 20 years have enabled users to tackle increasingly complex design challenges. Now, OptiStruct in combination with 3D printing helps to achieve more efficient structural designs.


By Uwe Schramm
Concept To Reality Winter/ Spring 2015
Subscribe to C2R Magazine




Optimization Drive Design - A Desktop Engineering Sponsored Report
Optimize every stage of product development with an integrated workflow that democratizes simulation and analysis. In this Desktop Engineering sponsored report Altair's vision for product optimization is analyzed

Computer Simulation's Role in Advancing Composite Aircraft Structures
Reprint of an article published on the December 2014 issue of Aerospace & Defense Technology magazine


Euro-Pro Embraces Simulation-Driven Design with Altair HyperWorks
Euro-Pro, maker of Ninja blenders and Shark vacuums, has embraced simulation-driven design to reduce physical tests and improve product performance and durability. HyperWorks solvers (OptiStruct, RADIOSS and AcuSolve) are used across the board via Altair’s HPC cloud infrastructure


Haier Redesigns Air Conditioners and Packaging with Altair HyperWorks to Eliminate Drop Damage
Haier Group is one of the world’s largest manufacturers of home appliances and consumer electronics. The company is the leader of its industry in China, where it is headquartered.



Haier ships its products all across the globe and in more than 100 countries, so well designed product packaging is crucial to the company’s ability to deliver products without damage to even the farthest destinations.



Download the Case study to see how Altair was able to reduce costs of physical testing and eliminate drop damage using simulated drop testing with HyperWorks.

Design of a Fuel Cell Race Car for the Annual Shell Eco-Marathon with Altair Products
The student team of the university of applied sciences in Munich participates in the annual Shell Eco-Marathon. The team has to develop a very light and highly efficient race car within less than a year. As there is no time for prototyping, simulation is mandatory. Altair provided the race team with the necessary software. The team secured 3rd place in the 2015 edition of the race!


Development Time Reduction at Stadler Rail
Dr. Alois Starlinger is talking about how Altair products made an impact in shortening development time at Stadler Rail.

Application of HyperWorks for Collaborative/Global Computer-Aided Engineering And Design Instruction at Brigham Young University
For a recent ME 471 class, a team of five students re-engineered the chassis/suspension platform for a 1969 Chevrolet Camero. At the conclusion of the project, the team presented a comprehensive review of their re-design vehicle to a panel of PACE program representatives and partners. Key to arriving at an efficient design was the early application of Altair topology optimization to the chassis, suspension, and wheel design of the vehicle. Altair HyperMesh was applied to generate finite element models that formed the basis for the topology optimization studies. The team results showed that 

The chassis mass was reduced by 34% through the application of topology optimization. The suspension control arm mass was reduced by 28%. The team was able to apply the Altair HyperWorks simulation tools in a seamless manner with the Catia-based CAD data that was generated for the vehicle re-design.

Climbing the Winner’s Podium with HyperWorks
HyperWorks allows for the option to increase the stiffness of the wheel shell through the use of OptiStruct. By applying HyperWorks to
their composite design and development process the team was able to increase the stiffness of the chosen components by 10 percent while learning how to do a structural layout of carbon fiber composites.

Design and Optimization of a High Performance C-Class Catamaran with HyperWorks
Born in 1961, based on a challenge between
Great Britain and the United States about who
builds the fastest catamarans, the ‘C-Class’
has been the driver of many innovations in
the world of multihull sailing.

Driving Million Dollar Savings at Ford using Structural Optimisation
The automotive business is a very competitive industry and in today’s markets, leading manufacturers are keen to find ways of reducing costs without compromising either quality or performance. This paper will cover the process of applying OptiStruct software to the re-development of a high volume and high cost plastic PAS (Power Assisted Steering) pump bracket into a much cheaper aluminium alternative. The outcome of this was a lighter, stiffer and cheaper replacement bracket that had the potential, based on the current production engine volumes, to save Ford Motor Company over $1.1 million a year.

Topology Optimization of Aircraft Wing Box Ribs
This paper considers the application of conventional energy based topology optimization methods for design of aircraft wing box ribs. Compared to standard topology optimization work undertaken at Airbus, the topology optimization of wing box ribs posed several additional challenges, mainly due to the wing box ribs being embedded in a redundant wing box structure. Several approaches to solving this problem have been investigated and are being reported as part of this paper, including a global analysis/optimization approach and two local analysis/optimization approaches.

Optimisation Techniques Leading the Development of a Steering Wheel
The early application of structural optimisation in the design of automotive components streamlines the design process and at the same time significantly increases the potential of the final design achieving maximum performance. This paper details the use of optimisation techniques during the development of a steering wheel, to generate an optimised design for cross attribute performance. This was completed in the Altair HyperWorks environment as Altair HyperMesh combined with Altair OptiStruct enables the creation of a parametric model with a multitude of design variables (i.e. size, shape, displacement, stress and frequency) in order to satisfy NVH, manufacturability, durability and crash targets.

The Complete Package: Applying Altair's Technology Process to Reusable Packaging Design
This paper demonstrates the flexibility that Altair technology provides throughout the design process with tools applicable to all stages. An overview of the LINPAC design process incorporating Altair's technology is given together with examples of how and which tools are being implemented. The limitations of the traditional LINPAC approach and the use of Altair's tools is demonstrated through the use of a detailed example; without the use of Altair technology, more iterations in expensive tool modifications would have been required to achieve a satisfactory design without introducing unacceptable costs.

Automotive Modal Testing Support and CAE Correlation Using Altair HyperWorks
To derive the natural frequencies and mode shapes of a given structure, the test Engineer has to decide on excitation positions that will efficiently excite all the modes of the structure in the frequency range of interest. Excitation positions are usually decided upon from experience or trial and error methods which can be time consuming and still not capture all of the modes in the selected frequency range. Using Altair HyperStudy and Radioss (bulk), Pre-test CAE analysis has been carried out to identify effective excitation positions before the commencement of modal testing, thereby significantly reducing pre-test lab time.

SOGECLAIR Aerospace Employs HyperWorks to Optimize Additively Manufactured Aircraft Components: Topology optimization of a large engine pylon structure
To find new development and manufacturing approach to reduce weight while ensuring safety, HyperWorks offers SOGECLAIR Aerospace an innovative, streamlined development environment with more design freedom, faster development cycles, and lower costs. A CAE-driven design process combining topology optimization using OptiStruct and Additive Layer Manufacturing (ALM).

World-Leading Crane Manufacturer TADANO FAUN Accelerates Its Design Processes with HyperWorks
Industry: Heavy Industry

Challenge: Generate accurate finite element method (FEM) calculations.

Altair Solution: FEM structural analysis utilizing the suite of HyperWorks tools

Benefits

•Faster time to results

•Flexible unit-based licensing model

•Cost reduction

Formidable Challenges in Formula Student Racing
Industry: University

Challenge: Remove weight and improve performance from vehicles

Altair Solution: Optimization with HyperWorks tools


Benefits:
  • Reduce weight of vehicle while
    keeping or increasing the component
    stiffness
  • Speed up time of development process
  • Save material and real-world testing
  • Reach top rankings during competitions


QinetiQ Keeps the Army’s Kiowa Copter Flying Lighter and Longer Through HyperWorks Optimization
A large proportion of Army aircraft are legacy platforms. Program managers of these aircraft are challenged to integrate new technology into these older platforms to enable them to meet the constantly expanding demands of today’s missions. These new devices and systems, however, often add weight to the vehicle or otherwise impact mission profiles. To sustain aircraft performance, weight reduction methods need to be adopted for aircraft components if technology insertions are going to continue.

Body-In-White Design for a Six-Passenger Sports Car Architecture: Maximizing Body Stiffness and Meeting Strength Requirements Using HyperWorks
The Deep Orange Program has partnered with Altair to apply advanced computational simulation methods to their vehicle designs. Altair-sponsored internships and fellowships have enhanced student learning through
providing webinar-based and on-sight instruction of Altair HyperWorks simulation technologies. An example of these simulation-based design applications is the CUICAR Deep Orange 3 Program,the third generation vehicle prototype designed and engineered by the Clemson engineering graduate students. Deep Orange 3 features a load-bearing structure based
on innovative sheet-folding technology and a unique 3+3 seating configuration package in a sports car architecture. The following describes this design and summarizes the application of Altair HyperWorks to meet the
necessary engineering structural performance requirements for the underlying body structure.


Improved Mechanical Performance and Reduced Cost of a Solar Panel System with HyperWorks
HyperWorks proved to be exceptionally valuable in Luxon’s work for a major producer of a large-scale industrial panel system, which measures approximately 50 x 70 feet and rotates to track the sun. The company had a system in production but sought to lower the cost of manufacturing. Additionally, Luxon’s customer wanted to expand the geographic locations where the system could be installed successfully, so it asked Luxon to develop
a more robust support structure to ensure that the system would survive the seismic,
wind and snow loading that the product was likely to encounter in various parts of the world.

Dante Sanchez Discusses the Optimization of Mabe's White Goods Packaging
For white goods manufacturer Mabe, the quality of the design and engineering of their home appliances is paramount. The objectives of this project were to simulate the effect of the distribution environment events to a washer and dryer product and perform optimization to improve product protection while reducing material costs and weight.

Renault
Carmakers the world over are investing heavily in the development of lighter vehicles and more economical engines that can go further on less fuel. Renault’s powertrain division wanted to further decrease the weight and increase the performance of existing and in-devolopment engines by redesigning key components to use a minimum amount of material. As an existing user of Altair’s simulation solutions, Renault approached Altair ProductDesign to assist in the development of the required optimization design methods and processes for use
at component and sub-system levels.

Assa Ashuach uses solidThinking Inspire to Optimise 3D Printed Stool Design
Industrial Research and product design consultancy Assa Ashuach Studio, design and manufacture lifestyle products and also limited edition studio pieces using new design and production methods to achieve unique forms and aesthetic qualities.

Success Story: M.TEC
M.TEC Engineering Continues to Benefit and Yield New Business Due to Advantages of the Altair Partner Alliance (APA)

RUAG Space Builds Reliable Satellites with HyperWorks
“Throughput time” or “Time to Market” is a key element for spacecraft structure. Structures are the first element required to start the integration of the spacecraft and it is essential that they can be delivered in time. However, late inputs require flexibility and efficiency to limit the impact on the development and manufacturing time.
This short video shows examples of automation and standardization of the analysis processes as implemented at RUAG Space using HyperWorks.


HyperWorks Helps Volkswagen Motorsport Develop a World Champion Polo R WRC
Since January 2013 Volkswagen Motorsport compete at the FIA World Rally Championship with the Polo R WRC. To improve the vehicle performance it is essential to reduce the cars weight and inertia. Drivers perform best lap times when they feeling well in the race car. So you have to meet drivers ergonomically needs. Also passive passenger protection is an important topic. To meet these requirements an own racing seat has been developed.

Design Development of a New Consumer Personal Care Product Pack Driven by Optimization
Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market fast, and at the necessary level of quality, presents a major engineering challenge. A new deodorant pack development process is described, which introduces advanced simulation and optimization technology into the concept development phase. Detailed predictions of interacting parts in a mechanism assembly are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction and helps to improve performance and reduce uncertainty in the development process.

The Application of Process Automation and Optimisation in the Rapid Development of New Passenger Vehicles at SAIC Motor
As a relatively young automotive company, SAIC Motor has drawn on the expertise of its UK Technical Centre to help in its objective to bring a new range of vehicles to market in an aggressive time frame. CAE has formed an integral part in doing this and the UK technical centre has worked closely with Altair Product Design amongst others to utilise its Engineers’ skills as well as the Hyperworks suite of software.

The paper aims to showcase what has been achieved to date, on the Roewe 550 medium car programme - currently on sale in China - and on another current vehicle programme, where processes have been developed further. Several interesting optimisation examples are highlighted in the development of the body structure as well as some key process improvement methodologies which have been jointly developed between SAIC and Altair to streamline the design process.

Targeting Composite Wing Performance – Optimising the Composite Lay-Up Design
This paper shows how Altair OptiStruct, part of the HyperWorks suite, is used to provide a complete solution when designing with laminated composites, taking the design through concept stages to producing the final ply lay-up sequence. The technology is applied to the design of a laminated wing cover to produce a mass optimised design which meets the requested structural targets.

Composite Optimisation of a Formula One Front Wing
This paper will show the application of a 3-stage approach to designing the optimum composite structure for a front wing on a Formula One car using Altair OptiStruct 9.0 Continual development of aerodynamic components is normal practice in the world of Formula One and the time taken to respond is paramount if a team is to be competitive.

Application of Optimisation Tools to the Design of Advanced Carbon Fibre Bicycle: FACTOR 001
FACTOR 001 is the result of a creative project by BERU f1systems to explore the transfer of design approaches, technology and materials from Formula One to a groundbreaking training bicycle. The design brief did not require the bicycle to comply with existing technical regulations, which resulted in great freedom during the design process. This paper details how OptiStruct Optimisation tools were used to help generate efficient lightweight solutions for the design of complex carbon fibre components. Free-size optimisation was used to generate laminate boundaries, ply thicknesses and fibre directions, which met stress and displacement requirements. Physical testing carried out on manufactured parts highlighted the accuracy of the FE models and demonstrated the advantages of incorporating OptiStruct Optimisation tools in the design process.

SimLab Tutorials - Linear Static Analysis of Connecting Rod
Create a local coordinate system; define contraints and loads; define contacts; create material and apply properties; export to solver and import results

SimLab Tutorials - Normal Mode Analysis of an Assembly
Create matching faces through assembly; assign load, mass and spring connection; assign material and properties; execute the analysis and verify results

SimLab Tutorials - Solver Setup for Non-Linear Analysis
Create group-based 3d bolts with pretension; apply user-defined contacts; create material with elasto-plastic curve; apply constraints and bearing pressure; create loadcases and define non-linear static solver settings

Providing Designers Easy Access to Powerful Simulation Tools
Brompton Bicycle discuss the benefits they have seen from moving away from simulation in their CAD system to a more powerful and flexible system from Altair.

Pranav Vikas Achieves 17% Material Savings with Light Weight and Optimised Product Designs using Altair HyperWorks™ Solutions
With over 2 decades of experience in manufacturing Aluminum Heat-exchangers such as Condensers, Evaporators, Heaters, Radiators, Oil Coolers, IHX and Roof AC units, Pranav Vikas (India) Private Limited (PVL) today is one of the largest and most diversified Heat-exchanger manufacturers in India. The company currently is the only fully integrated Condenser manufacturer in India with their own state-of-the-art Micro-tube facility at Ranjangaon, Pune. PVL serves leading global and Indian Original Equipment Manufacturers (OEMs) in the Passenger, Commercial, and Off-road vehicle segments.

Random Vibration Procedure and Best Practices
In order to evaluate if a design is robust and meets design margins, engineers use a variety of analytical tools. Often a product’s duty cycle is not perfectly characterized but the statistics of a lifetime of excitation are known.
These excitations can cause fatigue when system level dynamics are excited. It is very important to understand how a system responds to these excitations and how natural frequencies interact with each other.
Power spectral density (PSD) analysis, more commonly known as random response analysis, is used to determine stresses and strains in a system that is subjected to random excitations.

Fast contact method for speeding up solving finite element problems involving non-linear contact behavior
For large aerospace assemblies in finite element (FE) analysis problems, contact interaction between the surrounding bodies has to be established to simulate the load transferred between the components, like aircraft engine carrying bracket assemblies, spigots assemblies etc., and understand the effects of interaction between respective parts. In some cases, depending upon geometry of the assembly, the region of study may not be contact area but the stresses acting within the parts themselves. If there is no geometric or material non-linearity in such problems, a new contact formulation method known as Fast Contact can be used in these contact regions.

Snap-Fit Optimization for Achieving Desired Insertion and Retention Forces
Snap-fits are ubiquitous engineering features used to quickly and inexpensively assemble plastic parts. The geometric, material, and contact nonlinearities associated with snap-fit problems can present modeling challenges. Quasi-static solutions with explicit solvers are commonly used to analyze snapfits; however, OptiStruct’s nonlinear solver now possess the ability to solve these highly nonlinear problems implicitly. The first part of this study discusses an effective approach to using OptiStruct for the implicit finite element analysis of snap-fits. Once an accurate simulation model has been created, engineers typically make design changes in order to achieve desired insertion and retention forces. The second part of this study details how HyperMesh morphing and HyperStudy can be used to optimize the snap-fit design, resulting in desired insertion and retention forces while minimizing mass and ensuring structural integrity. The approach documented in this report can reduce the design time, material use, and failure rate of snap-fits used in industry.

Single Model Multi-Attribute Analysis & Optimization
On September 27th, OptiStruct users presented the latest capabilities and advancements in simulation-driven design methods for noise and vibration, durability and fatigue solutions. In addition, Altair experts showcased the unique OptiStruct development workflow which allows a baseline model to be analyzed and optimized for various criteria within one solver, in one format, with just one license.

Presentation recorded in Troy, MI during ATCx OptiStruct 2018 on September 27th, 2018.

Durability Workshop
On September 27th, OptiStruct users presented the latest capabilities and advancements in simulation-driven design methods for noise and vibration, durability and fatigue solutions. In addition, Altair experts showcased the unique OptiStruct development workflow which allows a baseline model to be analyzed and optimized for various criteria within one solver, in one format, with just one license.

Presentation recorded in Troy, MI during ATCx OptiStruct 2018 on September 27th, 2018.

Magneto-Vibro-Acoustic Efficient Design of PWM-Fed Induction Machines
Induction motors are widely used in the automotive industry. In order to increase the passenger’s comfort, motor designers try to develop new solutions to reduce the noise at its origin, on the electromagnetic side. Damper winding can be a solution to improve emitted vibration and noise. In this presentation, LSEE shows interesting modelling method to evaluate the impact of damper windings on the vibro-acoustic behavior of the motor considering PWM, and compares it with measurements.

* Please note this technology is patented / WO 2016207166 A1*
An LSEE & Altair presentation at SIA-CTTM Automotive NVH Comfort 2018


MBD Series: Lightweight Design
Tony Norton - Executive Vice President Product Design at Altair Engineering - talks about MBD being an essential tool in finding accurate loads for a subsequent optimization. He also introduces Inspire Motion and explains the Sub-Space Response Surface MDO Solution developed by his Product Development team.

Benefits of the Symbiosis of Topology Optimization and Additive Manufacturing in Architecture
The challenge was to investigate the potential offered by the symbiosis of topology optimization and additive manufacturing for architectural projects. The Altair solution included the use of the HyperWorks suite, especially OptiStruct for optimization tasks. The benefits were reduced construction time and costs due to decreased material usage while receiving better and more esthetic results.

ICAT Achieves Robust Structural Integrity of their Automotive Components using Altair HyperWorks®
The International Centre for Automotive Technology (ICAT) is an automotive testing and R&D centre. In their pursuit to carve a niche as a one-stop solution for the automotive industry’s needs in the areas of product design, testing and validation, the ICAT team required a very advanced suite of software solutions. They needed a software suite that would save them time, money and also help in all phases of product development. The Altair software suite has greatly helped the team in providing timely and appropriate solutions to their clients.

More Efficient and Economic Injection Mold Tools thanks to Topology Optimization, CFD Simulation and 3D Printing
Toolmaking is usually characterized by cost-intensive, custom made, single-unit production. To create innovative tools, the industry increasingly relies on new manufacturing methods such as 3D printing. To meet market demand, PROTIQ GmbH, a spinoff from Phoenix Contact needed to increase productivity through more efficient injection mold tools. The Altair solution included development of optimized tools using simulation, optimization and additive manufacturing (model setup with HyperMesh, topology optimization and FE analysis with OptiStruct, CFD analysis with AcuSolve and refinement with solidThinking Evolve. The benefits included increased productivity due to shorter production cycles, weight reduction of 75%, shortened development time and production costs reduced by 25%.

Efficient Injection Molding Tools through Optimization, CFD Simulation and 3D Printing
The company PROTIQ (www.protiq.com) worked with Altair and created a highly efficient molding tool. Optimization with OptiStruct was used to find the optimal design to guarantee the maximum tolerances of the generated products. The cooling process of the product was simulated with CFD (AcuSolve). As an overall result, the cycle time could be significantly decreased and the part quality also improved due to lower thermal deformations.

  •  
Altair Aerospace: Fail-safe and Multiphysics Optimization
This webinar covers the complete fail-safe optimization process of a wing rib starting with the search of a new and more efficient design to the calculation of optimum dimensions. The replacement of a metallic fitting by an organic 3D printed version, while increasing performances and decreasing mass reduction is discussed as well. HyperStudy has also been used to perform multi-disciplinary studies throughout the process.

Webinar: Structural and Thermal Coupling with Electromagnetic Systems
Electromagnetic phenomenon may induce undesired effects such as heat or vibrations. To predict and correct them by simulation, it is necessary to couple all phenomenon. Altair HyperWorks software suite is a perfect solution for this and in this webinar, two use cases will be demonstrated, where Flux is coupled with OptiStruct and AcuSolve.

ESAComp-HyperWorks Interface Recommended Workflows
The use of the ESAComp-HyperWorks interface for enhanced post-processing of laminated composite structures is introduced.

Sella Chair - Form Follows Performance
Short video describing the design and production of a design chair by Architect Atanas Zhelev (Digital Architects, Vienna, Austria). This design piece demonstrates the feasibility of his Active Grid Monocoque System (AGM) he uses in his work for highly curved, wide spun architecture. The analysis has been done with Altair products, foremost ESAComp and OptiStruct.

Altair MDO Director Datasheet
A multi-disciplinary optimization (MDO) approach allows you to explore all design requirements simultaneously and achieve lighter products, faster. Until now, enabling this process on live vehicle programs has been a challenge. Altair's MDO Director is a novel set of software tools that provides a process to rapidly set up, execute, post-process and explore the design of MDO problems.

Optimization of Photovoltaic (PV) Mounting Structures – Savings on Material and Cost
Photovoltaic specialist Thesan, a subsidiary of global manufacturer Savio S.p.A, manufactures, and distributes mounting structures, consisting of a so-called Purlin, a Rafter, and a Pole (and Hat), designed to withstand potentially occurring loads from wind and snow, as well as dead loads. Drawing on the Savio Group’s competence in the design of steel and aluminum structures and thanks to a team of over 40 engineers, they are to satisfy every construction requirement of photovoltaic power plants at all altitude and climatic conditions, using any specific fixation requirements. For a recent project requiring optimization of a mounting structure of a medium sized PV field with a power of 5 MW, engineers used HyperWorks. The benefits included reduced material usage, reduced manufacturing and transportation costs and improved competitiveness for Thesan.

Optimization-driven Product Development at Volvo
Harald Hasselblad (PhD) - Senior Analysis Engineer at Volvo Car Group Sweden - talks about introducing an Optimization Culture Arena to support simulation driven development in his company.

Robot Bike Co.
Developing a Fully Customizable, Additively Manufactured Mountain Bike

Additive Manufacturing of a Satellite Antenna Bracket
Analysis and design of a 3D printed antenna support for the Sentinel-1b satellite by RUAG Space with Altair Products.

Composite Rotor Blade Analysis using Altair HyperWorks
As part of a senior design project – the design and analysis of a coaxial rotor craft –
Christopher Van Damme, at the time of the project senior undergraduate student within the
department of Engineering Mechanics at the University of Wisconsin-Madison, had to analyze
a composite made helicopter rotor blade. In his analysis he had to employ Computer-Aided
Engineering tools to cover the required studies regarding static, modal, frequency response,
and dynamic analysis of the rotor.

Optimized Design for 3D Printed Valve Block Sheds Weight, Size and Gains Improved Performance
Not every component or product is suitable
for 3D printing, depending on its size, form
and design as well as the quantity needed.
A valve block is very suitable for 3D printing
and has a high potential for improvement in
weight, performance, and design freedom
when additively manufactured.

HyperWorks for Aerospace: Structural Solvers
This video summarizes the latest features of OptiStruct 14.0.120 which are very relevant for aerospace engineers. The topics discussed are new stress constraints for topology optimization, a 'fast contact' algorithm, tape laying manufacturing for composites, fail safe topology optimization, and resultant forces and moments as design criteria.

The webinar also touches on MotionSolve and RADIOSS as solvers for the Aerospace industry.


Digital Development at Hyundai Motor Group
Dr. Byungsik Kang is explaining how upfront engineering with FEA methods made a big impact at Hyundai Motor Group. He also explains the importance of designers using simulation for their own need at the early stage of development. Last but not least he is talking about the power of the solver OptiStruct to find entirely new designs.

Close Hauled with Hyperworks - Student Team of Politecnico di Torino Sails Away from Competition
The project focused on the design and construction of a skiff, a particular kind of sail boat, within the given regatta regulation. With its modeling and calculation tools, HyperWorks helped the team to significantly reduce weight while increasing stiffness, while saving time and costs.

Inspired by Nature: Electric Motorcycle goes 3D - Combining Topology Optimization, New Materials, and Additive Manufacturing in the Development of the Airbus APWorks Light Rider Results in a Revolutionary Lightweight Design
The Airbus APWorks Light Rider is the world's first 3D printed motorcycle prototype. Altair OptiStruct® was used for inspiration of its organic structure. Using additive manufacturing, a simulation-driven design process approach and topology optimization during the process achieved optimum lightweight design.

Adam Wais of Rolo Bikes Discusses the Working Relationship with Altair
During the development of a new carbon fiber bicycle, the design team at Sweden based Rolo Bikes, wanted to develop a frame which exhibited world leading strength and stiffness attributes while keeping weight to an absolute minimum. The team required an efficient process to design the frame and test it in a virtual world against the industry’s safety and performance standards.

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Lighter, farther, faster, greener: TUfast Eco team drives to success with HyperWorks
For the Shell Eco-marathon, an international contest for sustainable mobility, student teams from schools and universities all over the world design vehicles that are as energy-efficient as possible. After passing a technical check, the vehicles compete for energy efficiency. In this discipline the vehicles are evaluated for the vehicle’s reach per kWh. To compete in this category, a driver with a minimum weight of 50 kg has to drive a distance of 17.9 km in less than 43 minutes. The challenge for the TUfast Eco team was breaking the world record for efficient vehicles and participation in the Shell Eco-marathon. The Altair solution included topology optimization with HyperWorks.

Evolutionary Design in Chassis Technology
This paper details the use of the Thyssenkrupp eDICT process for the design of sheet metal chassis components. eDICT (evolutionary design in chassis technology) is an innovative structured process flow for the design of optimal structures. eDICT uses the optimisation capability of Optistruct with a set of custom tools to guide and translate a design into a production feasible sheet metal solution. Fundamentally it reverses the usual design loop of CAD first then CAE assessment. The function is used to determine the design and the form follows. On recent projects eDICT has produced 25% mass reductions compared to the current series design. eDICT is also able to reduce development times and resource with an efficient solution production right from the outset.

Delivering Innovation and Intelligence in Product Design
Packaging designers must constantly inject innovations to attract consumers in a constantly evolving and highly competitive market. Keeping ahead of the competition by bringing new and exciting products to market faster whilst maintaining quality, presents a major engineering challenge. A new packaging development process is described, which introduces advanced automated simulation and optimization technology right from the concept development phase. Detailed predictions of primary, secondary and tertiary packaging performance are made possible through use of advanced simulation technology. Design optimization is then employed using the modelling as a virtual testing ground for design variants. The approach provides clear design direction, an opportunity for wider experimentation, helps to improve performance and reduces uncertainty in the development process.

Balancing Manufacturability and Optimal Structural Performance for Laminate Composites through a Genetic Algorithm
This paper details the application of a specialised genetic algorithm to reduce the mass of a laminated composite wing rib. The genetic algorithm has been customised specifically to optimise the performance of polymer-laminated composites. The technology allows the mass to be minimized by the removal or addition of plies of various discrete orientations whilst satisfying the structural intent of the component. For the rib structure assessed, the structural constraints consist of limits placed on the displacement, stress (i.e. ply failure index) and buckling behaviour.

Design Optimization Applied to the Development of an Oilfield Bistable Expandable Sand Screen
This paper will cover the design, development, and testing of an expandable sand screen using bistable cell technology. In addition, the design and development of the proprietary expandable connection will be presented. The testing presented covers a wide range of structural integrity, expansion, sand retention, mudflow, and geomechanical tests performed on the screen, base pipe, and connection.

Aircraft Radome Multiphysics Using Simulation
Watch this webinar to see a demonstration of a multiphysics simulation approach using the Altair HyperWorks platform for the analysis of airborne radomes for electromagnetic , structural, aerodynamic, and bird strike performances.

Optimizing a Solar Car for Endurance and Energy Efficiency
Using Altair simulation software, Gurit supports Western Sydney University's Bridgestone World Solar Challenge team, helping them design the most efficient and aerodynamic
car possible, while ensuring driver safety
and adhering to class rules.

Design for Additive Manufacturing with Topology Optimization
Presentation by Avishai Warszawski, Mechanical Designer at IAI, Israel Aerospace Industries at the ATCx in Israel, Netanya on October 30, 2019.

The goal of this project is to design a lightweight and stiff support bracket for delicate coaxes which are attached to an electronic unit. The machining design of this bracket, although very light in weight, did not provide the required stiffness and was also very expensive to manufacture. The best approach for design was only realized after the AM team was requested to find a solution. Topology optimization with Altair tools was used to define the best shape that provides the best solution. Finally, the bracket was printed in an SLM machine from AlSi10Mg. In the near future it will be qualified by dynamic tests in accordance with the defined environmental loads.

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.


HyperWorks provides flexibility and agility to development processes of Engineering Services Provider Beta Epsilon
Beta Epsilon designs racing cars and offers engineering. Beta Epsilon offers component and vehicle meshing, FEA analysis of metal and composite components, crash test simulation, optimization, and CFD simulation. Beta Epsilon uses HyperMesh, OptiStruct, HyperCrash, RADIOSS, AcuSolve, HyperView, and Virtual Wind Tunnel. With HyperWorks, Beta Epsilon could improve the quality of its products and extend its range of services.

Cal Poly Pomona Uses HyperWorks to Design a Winning Formula SAE Racecar
Cal Poly Pomona applies HyperWorks to optimize the design of a new wheel shell and analyze laminates for a SAE Formula student racecar.


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Originating a safe Fun Utility Vehicle (FUV)
The challenge in the development of Arcimoto’s SRK Generation 8; an all-electric, multi-purpose/utility commuter vehicle, included creation of an optimized platform that offers
3-wheeled stability, a space frame enclosure for protection, and a rear swing arm that handles the load requirements and also follows the visual design of the vehicle. HyperMesh® provided an environment for rapid model generation allowing Arcimoto to answer queries by helping them perform the analysis in OptiStruct® in an easy, time efficient manner. Using RADIOSS® for the physics helped them achieve repeatable and accurate results, reduce simulation cycle times and allow for evaluating multiple design scenarios thus enabling better decisions.


Subros Leverages Altair HyperWorks® to Build Optimized Product Designs While Reducing 60% Simulation Time and 40% Prototyping Costs
Subros is the leading manufacturer of thermal products for automotive applications in India and operates in technical collaboration with Denso. Being a major supplier of AC units to the predominant automotive segments and all classes of vehicles produced by global players in the country, it is very important for Subros to honor deadlines of product delivery with agreed benchmarks of quality. The Subros team has used Altair solutions such HyperMesh for FE modeling, RADIOSS and OptiStruct for structural analysis, AcuSolve for flow analysis, and solidThinking Inspire for Modal Analysis

HyperWorks 2017: Optimization Driven Design
Design optimization manifests itself in all levels of Altair’s offerings; software, product design and packaged solutions. This is all carefully planned and implemented so that the engineers and analysts can benefit from these functionalities without leaving their native environments.

ICAT Meets Automotive Safety and Regulatory Requirements with Altair Simulation Software
ICAT is one of the leading centres for testing, R&D, design, development and validation in support of a Government of India funded initiative to develop facilities for automotive testing & development. To meet the challenges of the automotive industry, they need to employ optimization to decrease vehicle weight while maintaining proper strength. For a major challenge for the rollover testing for bus industry, they used Altair Radioss for roll over simulation and Altair OptiStruct for optimization leading to shortened development time for their customers by over 50%.

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