The frame design of the Airbus APWorks' Light Rider that will be displayed at the event is an excellent example of the symbiosis of topology optimization and additive manufacturing. Its structure is based on optimization results generated with Altair's OptiStruct® technology, supported by HyperMesh® for pre-processing tasks such as meshing, and HyperView® for post-processing the analysis results. All products are part of the HyperWorks CAE simulation suite. Applying a typical topology optimization OptiStruct run, the APWorks engineers first defined the design space (areas where the optimization technology can and cannot remove material, such as fixing points or access holes) and applied general loads and boundary conditions. The optimization software then created a design proposal that fulfilled the frame's structural requirements, by generating highly innovative geometries.
The cast aluminum component also to be displayed at the booth was designed and optimized with Inspire, then nCode DesignLife was applied to conduct a fatigue analysis and finally solidThinking's Click2Cast® software was used for a casting simulation. The created design resulted in a casting mold, 3D-printed by voxeljet. This process ensured that the component benefited from all of the positive characteristics 3D printing and casting offer.
"We are very much looking forward to presenting our solutions, including our Simulation-driven Innovation approach at formnext," said Mirko Bromberger, Director Marketing and Additive Manufacturing Strategies at Altair Engineering. "Additive manufacturing (AM) is making headlines across industry as companies discover and take advantage of the inherent flexibility as well as the potential weight advantages the method offers, when combined with design optimization techniques. As we will present with the example of the Light Rider, when topology optimization and additive manufacturing are combined, it is possible to produce a structure that is lighter and stiffer than a traditionally manufactured part. The visitors of formnext can expect a very broad and informative program, highlighting solutions for the different production and engineering disciplines."
Visit Altair at formnext, hall 3.1/booth E 50 and at the TCT conference programs in hall 4.2.
Founded in 1985, Altair is focused on the development and application of simulation technology to synthesize and optimize designs, processes and decisions for improved business performance. Privately held with more than 2,600 employees, Altair is headquartered in Troy, Michigan, USA with more than 45 offices throughout 20 countries, and serves more than 5,000 corporate clients across broad industry segments. To learn more, please visit www.altair.com.
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