Altair Megacasting

Realize the full potential of your products with AI-powered generative design


Today’s need for sustainable mobility solutions and the emergence of revolutionary new vehicle concepts has inspired designers to rethink ways of minimizing weight, manufacturing costs, and how to meet the latest performance targets. Reduce the risks involved in moving from the traditional to the new with Altair’s comprehensive solution for developing innovative mega- and gigacasting components. Blending industry knowledge and innovative technologies, explore how a bespoke workflow utilizing Altair's artificial intelligence (AI) and generative design approach, powered by advanced CAE, delivers multidisciplinary automotive design exploration while also allowing teams to leverage thousands of simulations to guide the best way forward.

Developing a Comprehensive Optimization Workflow for AI-Powered Generative Design

  • Topology optimization. Deploy a proven, powerful generative engineering technique to identify where to place material most effectively. Derive optimal load-paths for multidisciplinary loading conditions comprising hundreds of load cases and variables covering crash, statics, driving dynamics, noise, vibration, and harshness (NVH), and manufacturing constraints for casting.
  • Powered by AI/ML. Utilize AI-unsupervised learning clustering to determine performance indicators for classification constraints, derived from simulation results of hundreds of samples within RSM optimization.
  • Multidisciplinary optimization. Response-surface based optimization with machine learning can be utilized to run crashworthiness analysis, meet design targets, and provide optimal rib orientations and thickness distribution for cast structures in nonlinear crash and casting simulation. Overcome pure scalar, regression type targets with clustering and classification of full simulation result fields to align with expert evaluation.
  • Manufacturability. Altair's design for manufacturing workflow allows exploration of the manufacturability of several different variants, identifying the optimal inlet number, size, location, and flow velocity at the gate for the high pressure die casting (HPDC) process.
  • Casting simulation. Explore a fast, easy, and accurate casting simulation tool fully compatible with Altair's AI tools. Focus on creating high-quality components with increased profitability through an intuitive user experience with Altair® Inspire™ Cast. Suitable for beginners and experts alike, from product designers to foundry engineers. Visualize typical casting defects from an early design phase and rectify them to avoid costly downstream corrections. 

Why Altair for Megacasting?

  • Innovation. Introducing a superior approach to achieve weight-optimized designs, better performance, and faster turnaround time compared to a traditional workflow for body-in-white (BIW) automotive structures.
  • Integration. Altair’s industry-ready workflow maximizes the efficacy of established automotive industry methods such as topology optimization and enhanced response-surface based (RSM) optimization by combining with artificial intelligence (AI) techniques such as machine learning (ML) based clustering and classification.
  • Customization. A customizable workflow for anyone exploring the benefits of mega- and giga-casting of complex structural parts using Altair’s unified, fully integrated platform. Discover a complete solution for state-of-the-art engineering simulation, AI, and high-performance computing (HPC) technologies, including advanced CAE capabilities and specialized solutions for automotive castings.

Vehicle Developers' eGuide

AI-powered Generative Design for Megacasting

Get ready to revolutionize your design process with your ultimate guide to AI-powered generative design. Explore cutting-edge insights and expert tips that will redefine the way you approach vehicle design. 

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