Structural optimization is an essential part of the design process while engineering hardware products. As a designer, you have to make tradeoffs to balance multiple design objectives, including cost, materials, and manufacturing constraints.Luckily, the fundamental design tools in an engineer’s arsenal are very similar whether you’re designing products for additive manufacturing or a traditional process. They include modeling techniques like latticing, shelling, perforation patterns, ribbing, and simulation-based methods, like topology optimization.The following design tips will help you tackle your design optimization problems. You will also find links to video demos and tutorials throughout the article to show you how to apply these techniques.<h2 id="isPasted">#1 Use the “shell &amp; infill” method as the benchmark</h2>The “shell &amp; infill” approach is one of the most common ways to reduce the weight of non-critical parts for additive manufacturing. It applies to any 3D printing process — from extrusion-based technologies and resin 3D printing to metal and polymer powder bed fusion.The shell bears the majority of the loads, while the internal lattice provides extra stiffness and reduces the likelihood of failures during manufacturing.Despite its simplicity, the “shell and infill” method is very effective and should always be your starting point — especially when you need to preserve the external shape of your part. It is commonly used in additive manufacturing production and can lead to a <a href="https://ntopology.com/case-studies/dmg-mori-robot-end-effector/" target="_blank">weight reduction of more than 60%</a>,<blockquote>Pro Tip: Don’t forget to add holes or openings for powder removal or resin evacuation.</blockquote><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQzNjc0NTE1NTQ4LURNRy1NT1JJLWxpZ2h0d2VpdGhpbmctcHJvY2Vzcy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">This key component of DMG MORI’s industrial automation robotic system was redesigned using the “shell &amp; infill” approach — it is 62% lighter and has 60% fewer components than the initial design.<h2 id="isPasted">#2 Vary the thickness of a shell using simulation data</h2>For structural components, varying the thickness of the shell ensures that stresses can remain within the safe limit at critical locations without adding unnecessary material throughout the part. There are two main ways to create a refined shell of variable thickness.One way is to manually assign a thickness to each surface of your part, thicken them separately and then combine them using a boolean operation.Alternatively, you can run a structural analysis on your original part — for example, a static analysis — and then use the results to create a shell that smoothly transitions between two predefined levels of thickness; thicker where stresses are high and thinner where stresses are low.Here’s a video that shows you how to apply step-by-step <a href="https://ntopology.com/videos/video/ntop-live-automotive-lightweighting-beyond-topology-optimization/" target="_blank">simulation-driven variable shelling</a> Field-Driven Design.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQzNjc0NTYwODM4LUxpZ2h0d2VpZ2h0LUF1dG9tb3RpdmUtQnJhY2tldC1WYXJpYWJsZS1TaGVsbC0xMDI0eDU1Ny5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">This automotive bracket was first topology optimized and then shelled to improve its crashworthiness — a static analysis is driving the thickness of the shell wall.&nbsp;<h2 id="isPasted">#3 Create a graded lattice driven by topology optimization</h2>You can also use a similar <a href="https://ntopology.com/field-driven-design/" target="_blank">field-driven design</a> approach to control other design elements. In the example below, the results of topology optimization on this ALCOA bracket were used to drive the thickness of the internal lattice.This hybrid approach combines the benefits of the “shell &amp; lattice” approach (easy manufacturability, compliance to an external shape, and so on) while grasping some of the high stiffness-to-weight ratios of topology optimization.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQzNjc0NjI5OTk3LWxhdHRpY2UtZHJpdmVuLWJ5LXRvcG9sb2d5LW9wdGltaXphdGlvbi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">The topology optimization results were used to drive the thickness of the internal lattice of this ALCOA aircraft bracket.&nbsp;<h2 id="isPasted">#4 Let simulation inform your lattice selection</h2>There are multiple variables that you should consider when designing a lattice structure — unit cell type, cell size, beam or wall thickness, cell map orientation, and so on.An iterative simulation-driven approach is the fastest and cheapest way to make the best design decision. There are three main methods that you can use to simulate a lattice.<h3>FE-based simulation</h3>A finite element analysis will provide the most accurate results, but it is 10x to 60x times more time-intensive than the other methods.<h3>Beam-based simulation</h3>An FE simulation that uses only beam elements will provide quick and (relatively) accurate results — but it’s not an option for TPMS lattices (like gyroids) or plate-based lattices (like hexagonal honeycombs).<h3>Homogenization</h3>This is the quickest method to approximate the behavior of a lattice-based on the geometry of a single unit cell. However, it is the least accurate for smaller lattices with less than a few hundred unit cells.<blockquote>Pro Tip: Run a small computational Design of Experiments first using beam elements or homogenization and then run a detailed FE analysis — or a test print — to validate the results.</blockquote><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQzNjc0NjYzNTk4LWxhdHRpY2UtZGVzaWduLXdpdGgtc2ltdWxhdGlvbi0xMDI0eDY2NSAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">The lattice of this bracket was optimized following an interactive design process that was automated using scripting in nTopCL.<h2 id="isPasted">#5 Perform a sensitivity analysis for “optimum” topology optimization</h2>Speaking of topology optimization, here’s something that you should never forget:<blockquote>The results of topology optimization are only as good as the boundary conditions used to produce them.</blockquote>There are many knobs to turn when running an analysis using topology optimization. Despite the name, not all results are equally optimal. For this reason, running a sensitivity analysis to tweak important input parameters is always a good idea.For example, when you apply different <a href="https://ntopology.com/videos/video/ntop-live-topology-optimization-boundary-penalty-for-truly-optimal-results/" target="_blank">boundary penalties</a> or <a href="https://ntopology.com/videos/video/ntop-live-stress-constraint-for-topology-optimization/" target="_blank">stress constraints</a>, the outcome of the optimization process will perform differently on important performance metrics.<h2>#6 Add perforations to traditionally manufactured parts</h2>Perforations patterns are holes of circular (or other) cross-sections on the surface of a part. In the context of lightweighting, perforation patterns can be a powerful tool when designing parts for traditional technologies — like CNC machining or injection molding.Compared to the other lightweighting design techniques, perforation patterns may seem simplistic. However, they can lead to significant weight reduction while providing superior stiffness, vibration resistance, and fatigue strength.For example, this <a href="https://ntopology.com/webinars/webinar/advanced-topology-optimization-for-aerospace-dynamic-analysis-manufacturability-cost/" target="_blank">aircraft elevator bracket</a> is 40% lighter than the original design, while its topology optimized counterpart is 68% lighter. However, the maximum displacement and stress of the bracket with the hexagonal perforation patterns are respectively 10x and 3x lower than the pure topology optimization result.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjQzNjc0NzAxMDkwLWFpcmNyYWZ0LWVsZXZldG9yLWJyYWNrZXQtaGV4LXBlcmZvcmF0aW9ucy0xMDI0eDU3Ni5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">This aircraft elevator bracket combines hexagonal perforation patterns with topology optimization and can be manufactured using CNC machining.&nbsp;<h3 id="isPasted">#7 Apply a rib grid to reinforce thin-walled parts</h3>Rib grids conform to a surface of thin-walled parts and increase their stiffness and resistance to buckling and bending. Rib grids find widespread use in aerospace components, as well as plastic injection molded parts or metal casts or forgings. There are four main variations of rib grids.<h3>Isogrids</h3>Isogrid ribs use a triangular pattern that increases the structure’s stiffness isotropically, distributing the load evenly and efficiently. For this reason, they are prevalent in aerospace applications.<h3>Orthogrids</h3>Orthogrid ribs use a square or rectangular pattern that is lighter and can provide anisotropic support. They are more common in non-critical applications.<h3>Honeycomb grids</h3>Honeycomb rib grids use a hexagonal pattern to create stiff structures. They are commonly used in sandwich structures, or injection molded parts to avoid warping.<h3>Voronoi ribs</h3>Voronoi rib grids create an organic-looking grid based on random points. Because of their unique aesthetics, Voronoi ribs find applications mainly in industrial design and consumer hardware. They are also more common in 3D printed products.<blockquote>Pro Tip:&nbsp;Think of rib grids as a lattice that conforms to a surface. You can use the same techniques to manipulate either a volume lattice or a rib grid.</blockquote>The example below shows an injection molded part. <a href="https://ntopology.com/videos/video/ntop-live-topology-optimization-of-injection-molded-car-pedal-ribs/" target="_blank">The distribution or direction of triangular ribs</a> was modified based on topology optimization results to generate this complex rib pattern.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1643674759610-ribs-driven-by-topology-optimization-1024x531.jpg" style="width: 766px;" class="fr-fic fr-dib">The distribution of ribs on this motorcycle swing arm was guided by a topology optimization study.&nbsp;<h2 id="isPasted">Key Takeaways</h2>Structural and multidisciplinary optimization combines computer methods and simulation with the designer’s experience and engineering knowledge. Through smart design, you can create a finished product that is lighter and has higher efficiency, reliability, and overall quality.Here are the three main takeaways to get you started:<ol><li>When designing for additive, begin with a simple “shell and infill” as your benchmark.</li><li>Use topology optimization and simulation data to drive key design variables and refine your design.</li><li>Perforation patterns and ribs are especially useful when designing for traditional manufacturing.</li></ol><hr>This case study was first published on the&nbsp;<a href="https://ntopology.com/blog/2022/01/26/design-tips-structural-optimization-lightweighting/" id="isPasted" rel="noopener noreferrer" target="_blank">nTopology blog</a>.

The lattice of this bracket was optimized following an interactive design process that was automated using scripting in nTopCL.

Lightweighting means more than just reducing mass. Through smart design techniques, you can maximize product functionality and minimize costs. Here are seven design tips for efficient structural design.

7 Design Tips for Structural Optimization & Lightweighting

This is the fourth of <a href="https://www.wevolver.com/article/simulation-driven-design-the-secret-to-better-products-in-less-time" target="_blank">five articles</a> in a series about simulation tools sponsored by Altair. Altair is hosting the free virtual global event,&nbsp;<a href="https://hubs.ly/H0-wpBD0" rel="noopener noreferrer" target="_blank">Don&#39;t Be Late To Simulate</a>&nbsp;on November 30, 2021: 2:00 p.m. (Paris) and at 8:00 a.m. (New York). &nbsp;As part of the program, Altair&rsquo;s director of global business development manager, and applications engineer Ujwal Patnaik and Chris Sambell will present the one-hour workshop: The Role of Simulation From Concept Development to Final Design. They will use the example of a belt-sander to demonstrate the many ways simulation can be used to optimize and improve the design process, leading to more efficient products and reducing time to market.&nbsp;<h3 dir="ltr" id="isPasted">The new paradigm of product development</h3>While most product design companies plan new product road maps with a customer-centric approach, many products still fail in the market. Common reasons for this failure include:&nbsp;<ul><li dir="ltr">New products evolve from customers&#39; functional requirements but are often compromised with strict time-to-market timelines.</li><li dir="ltr">Products are becoming more complex, and product teams do not have time to innovate, which may lead to mediocre product design or over-design.</li><li dir="ltr">In the product development cycle, teams may struggle to have the expertise to run simulation - missing out on valuable insights.</li><li dir="ltr">Because of a lack of simulation experts, some companies only use simulation to validate designs after most product choices have been determined explicitly or implicitly, leading to product failures or products with manufacturing defects.</li></ul>Product teams see the benefits of incorporating simulation into their design process in three key areas:<ul><li dir="ltr">Time-to-Market. Research has shown that 72% of products created with simulation meet product launch date targets, versus only 50% of products for non-simulation users. 1</li><li dir="ltr">Cost. Simulation assists in meeting costs in both design and manufacturing. &nbsp;&nbsp;</li><li dir="ltr">Quality. Companies that have switched to an incorporated simulation report a 27% increase in meeting quality targets.&nbsp;</li></ul>In the <a href="https://hubs.ly/H0-wpBD0" target="_blank">upcoming workshop</a>, engineers from Altair will go through the product engineering of a belt sander using the Altair Inspire and Altair SimLab products.&nbsp;<h4 dir="ltr">Multiphysics Simulation with Altair</h4><a href="https://www.altair.com/inspire/" target="_blank">Inspire</a> enables design engineers to create, modify, and defeature solid models quickly, enabling the creation, optimization, and study of innovative, structurally efficient parts and assemblies. The software assists both simulation analysts and designers to perform what-if studies faster, easier, but most critically earlier, encouraging collaboration and reducing product time to market.<a href="https://www.altair.com/simlab/" target="_blank">SimLab</a> is a process-oriented multidisciplinary simulation environment to analyze the performance of complex assemblies. Multiple physics, including structural, thermal, and fluid dynamics, can be easily set up using automated modeling tasks, helping to reduce the time spent creating finite element models and interpreting results.&nbsp;<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3NjU3MDA3ODQ4LUlNQUdFIDUtMDEgKDQpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">Simulation reduces the design cycle length.</div><h3 dir="ltr" id="isPasted">Using Simulation From Concept Development to Final Design: Workshop</h3>A belt sander is used in shaping and finishing wood and other materials. It&rsquo;s a complex tool that has an electric motor that turns a pair of drums on which a continuous loop of the sandpaper smoothes the surface. While a very practical object, the design must also consider aesthetics and ergonomics, as well as user comfort by controlling noise and vibration levels. There are many steps to the design and simulation plays a critical role in not only designing an efficient and desirable product but is used to test manufacturing possibilities, durability, and safety.&nbsp;A belt sander has a lot of plastic parts in the casing and handle. It&#39;s important to ensure that these parts of the belt sander are within the range of the required dimensions and that the resulting design can be effectively and efficiently manufactured. To achieve this, the first step is to conduct a concept design analysis of the belt sander external housing and optimize the internal rib pattern to improve stiffness and reduce weight.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3NjU2NDE0NzkzLUJlbHRfU2FuZGVyX0dSSVQxMl80S19BQjAyIHNtb2wucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 788px;" class="fr-fic fr-dib">Later in the process, the optimized design will go through the manufacturing process with a filling, packing, cooling, and warpage analysis. A material characterization (short fibers) is also completed to conduct stress analysis and detail validation studies. This battery of tests includes drop tests, &nbsp;3-point bending, and fluid dynamic analysis to interrogate the product&#39;s cooling ability. In this test, the conjugate heat transfer is tested while the motor is in function to clearly understand the cooling and heating cycle of this product. Once it satisfies all the design &amp; validation requirements, you have a belt sander ready to manufacture.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1637656802209-ezgif.com-gif-maker+%282%29.gif" style="width: 788px;" class="fr-fic fr-dib">The workshop will go into detail about how to resolve the above challenges and will also &nbsp;showcase a few additional benefits, including:<ul><li dir="ltr">Identifying the right simulation tool for the right job</li><li dir="ltr">Simulation continuity&nbsp;</li><li dir="ltr">Unified interface for multiple physics.</li></ul>The workshop is part of the global virtual event, <a href="https://hubs.ly/H0-wpBD0" rel="noopener noreferrer" target="_blank">Don&rsquo;t Be Late To Simulate</a> on November 30. Register to secure your place in the workshop and check out the full list of speakers on the <a href="https://hubs.ly/H0-wpBD0" target="_blank">event page</a>.&nbsp;This is the fourth of <a href="https://www.wevolver.com/article/simulation-driven-design-the-secret-to-better-products-in-less-time" target="_blank">five articles</a> in a series about simulation tools. The series covers case studies on using simulation in product design and explores the applications of multiphysics simulation.&nbsp;Article #1 is about <a href="https://www.wevolver.com/article/simulation-driven-design-the-secret-to-better-products-in-less-time" rel="noopener noreferrer" target="_blank">how simulation tools improve the development process, enabling engineers to deliver better products in less time.</a>Article #2 <a href="https://www.wevolver.com/article/why-cad-based-simulation-can-become-a-game-of-cat-and-mouse" rel="noopener noreferrer" target="_blank">demonstrates w</a><a href="https://www.wevolver.com/article/why-cad-based-simulation-can-become-a-game-of-cat-and-mouse" rel="noopener noreferrer" target="_blank">hy CAD-based Simulation Can Become a Game of Cat and Mouse.</a>Article #3 is for <a href="https://www.wevolver.com/article/pressing-for-change-at-atna" rel="noopener noreferrer" target="_blank">advanced simulation tools that helped this German startup design a press machine that plays a role in reducing carbon emissions.</a>Article #5 speaks for the&nbsp;<a href="https://www.wevolver.com/article/an-engineers-guide-to-multiphysics-modeling-real-world-behaviour-and-predicting-performance" rel="noopener noreferrer" target="_blank">advances in software and increased access to inexpensive compute power means more and more engineers can use Multiphysics analysis to improve their design processes.</a><h2 dir="ltr" id="isPasted">About the sponsor: Altair</h2>Altair is a global technology company, which provides software and cloud solutions in the areas of simulation, high-performance computing (HPC), and artificial intelligence (AI). Altair enables organizations in nearly every industry to compete more effectively in a connected world while creating a more sustainable future. &nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3NjU3MTc1NDg4LWxvZ28gYmFubmVyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib"> <h2>References and further reading</h2><ol><li dir="ltr"><a href="https://www.aberdeen.com/featured/meeting-manufacturing-business-goals-multiphysics-simulation/" target="_blank">https://www.aberdeen.com/featured/meeting-manufacturing-business-goals-multiphysics-simulation/</a></li></ol>

Article #4 of our simulation series. This article previews a workshop that will take place at the Don’t be Late to Simulate event on November 30. 

Simulation-driven design for product engineers

<a href="https://www.atna-solutions.com/en/" rel="noopener noreferrer" target="_blank">ATNA Industrial Solutions</a> GmbH started as a spin-off of the German Technical University Bergakademie Freiberg (TU Freiberg) following a research project funded by the German program EXIST for business startups. As part of this two-year project, four engineers developed a new hydraulic press machine for briquetting &ndash; a technology compressing material into solid shapes/ briquettes &ndash; and built their first prototype.&nbsp;The success of this prototype, which delivered high quality at a high throughput, inspired the team to start ATNA &ndash; a startup with the vision to revolutionize briquetting by building better and more efficient briquetting presses. The concept of briquetting has become popular for various raw materials (wood, straw, coal) and waste materials (sludge, PU foam, plastic shreds) and so the demand for flexible and efficient pressing machines is high.&nbsp;<h2 dir="ltr" id="isPasted">The Challenge</h2>The demand for biomass briquetting is steadily increasing as the use of brown coal fuel is being dramatically reduced to meet CO2 emission targets in the near future. Many big plants across Europe will stop producing brown coal briquettes by the end of 2022. To address this trend and growing demand for alternative fuel options, ATNA set out to develop a new generation of briquetting presses.&nbsp;While conventional briquetting presses such as the roller press achieve high throughputs, they have limitations in producing high-quality briquettes of difficult raw material. On the other hand, conventional hydraulic presses can achieve a high quality, but deliver only a low throughput. &nbsp;ATNA&rsquo;s goal was to design an improved hydraulic press which can achieve the high throughput of a roller press while delivering a high briquette quality.&nbsp;<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3MTQxNzI2MTU1LWJyaWNrLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">A briquette produced by ATNA.</div>To begin to design this system, the team used a CAD embedded FEA system available to them, to study subassemblies. However, limitations in the system made this a cumbersome and time-consuming task and ATNA were not able to analyze the entire system. As a result, simulation was strictly limited to absolutely necessary calculations of forces and resulting stresses on the parts. To accomplish their design targets, however, the startup needed simulation tools that help them to get the bigger picture and would deliver an overall assessment of their new designs to speed up their development process.&nbsp;<hr>Thomas M&uuml;ller co-founder and Commercial Manager, ATNA Industrial Solutions will present at the Don&rsquo;t Be Late to Simulate event on November 30. Thomas will discuss the story of ATNA outlining the challenges and benefits of using simulation and how it now drives their design process. <a href="https://hubs.ly/H0-wpBD0" target="_blank">Learn more about Thomas&rsquo;s presentation here.</a>&nbsp;<hr><h2 dir="ltr" id="isPasted">Simulation Solutions with Altair</h2>ATNA was offered to implement Altair SimSolid&reg; under the global Altair Startup program which is tailored to the needs of high-tech startups offering access to all types of simulation, high-performance computing, and artificial intelligence solutions at an affordable price. Altair SimSolid&reg; is a simulation package that enables fast structural analyses. It eliminates geometry preparation and meshing: the two most time-consuming, expertise-extensive, and error-prone tasks performed in a conventional structural simulation. For the ATNA engineers, the structural simulation tool allowed them to virtually simulate entire machines quickly and efficiently with a high degree of accuracy.&nbsp;<div class="fr-img-space-wrap"><div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3MTQwODU5MjcxLW1hY2hpbmUuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">Altair&reg; SimSolid&reg;simulation result of all load-carrying elements of the ATNA briquetting press.</div></div>The developers applied SimSolid to structurally design their briquetting press that can produce briquettes in a multistage pressing process (pre-compacting, pre-pressing, main pressing, and extraction) and realized high throughputs with low energy consumption. &nbsp;SimSolid enabled the ATNA team to study complete complex assemblies, including more than 2800 parts, accurate forces, and resulting stresses of the entire system, and provided an overall structural insight on the machine&rsquo;s behavior.&nbsp;It allowed the engineers to make assessments during design revisions by running simulations on the fly to detect disadvantageous operational conditions and design faults. While it took the ATNA engineers several days to calculate even small model changes with the traditional finite element method (FEM) tool, SimSolid provided them with initial results within 30 seconds.&nbsp;ATNA also applies SimSolid to customize presses tailored to customer requirements, such as special operating conditions including high pressures up to 5600 kilonewtons. With SimSolid, ATNA can now study how the design affects the deflection of these pressures and thus the entire structure.<h2 dir="ltr">Why fast innovation is more important than ever</h2>Responding to the climate crisis must be a priority for engineers everywhere. Simulation will play a key role in delivering the exponential innovation needed to transform industries away from fossil-fuel dependency. In the past simulation was limited to large design teams with expansive budgets, but now specialized simulation software is available more democratically and designers at all levels can incorporate simulation from the very beginning of their design cycles.&nbsp;Simulation offers the possibility for rapid iteration and testing as seen by Atna to help develop products not only with more speed but with a finished product that is more efficient, and specific. Simulation can be applied not only in the design stage of product development but in the monitoring and revision of existing systems such as through the use of digital twins as well as a low resource method to speculate on future technologies and products.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3MTQwOTI5MTk5LUFUTkFfU2ltU29saWRfVGFiZWxsZSAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 788px;" class="fr-fic fr-dib"><h2 dir="ltr" id="isPasted">Speed up of the simulation process with Simsolid at ATNA</h2>This is the third of five articles in a series about simulation tools sponsored by simulation software provider Altair. Future articles will cover case studies on using simulation in product design, workshops on how to get started with advanced simulation software, and explore the applications of multiphysics simulation.&nbsp;Altair are hosting the free virtual global event, <a href="https://hubs.ly/H0-wpBD0" rel="noopener noreferrer" target="_blank">Don&#39;t Be Late To Simulate</a>&nbsp;on November 30, 2021, | 2:00 p.m. (Paris) and at 8:00 a.m. (New York).Thomas M&uuml;ller co-founder and Commercial Manager, ATNA Industrial Solutions will present the session titled, Simulation under Pressure: How SimSolid Changes Everything in FEA about ATNA&rsquo;s use of simulation. He will discuss the design process of ATNA outlining the challenges of fulfilling both customer flexibility and rigorous adherence to quality and safety standards. With limited resources, ATNA was able to use simulation as a design tool to deliver a machine design that exceeded both expectations. <a href="https://hubs.ly/H0-wpBD0" target="_blank">To check out this session, or any of the others register on the event page here.</a>&nbsp;Article #1 is about <a href="https://www.wevolver.com/article/simulation-driven-design-the-secret-to-better-products-in-less-time" rel="noopener noreferrer" target="_blank">how simulation tools improve the development process, enabling engineers to deliver better products in less time.</a>Article #2 <a href="https://www.wevolver.com/article/why-cad-based-simulation-can-become-a-game-of-cat-and-mouse" rel="noopener noreferrer" target="_blank">demonstrates w</a><a href="https://www.wevolver.com/article/why-cad-based-simulation-can-become-a-game-of-cat-and-mouse" rel="noopener noreferrer" target="_blank">hy CAD-based Simulation Can Become a Game of Cat and Mouse.</a>Article #4 <a href="https://www.wevolver.com/article/simulation-driven-design-for-product-engineers" rel="noopener noreferrer" target="_blank">previews a workshop that will take place at the Don&rsquo;t be Late to Simulate event on November 30.</a>Article #5 speaks for the&nbsp;<a href="https://www.wevolver.com/article/an-engineers-guide-to-multiphysics-modeling-real-world-behaviour-and-predicting-performance" rel="noopener noreferrer" target="_blank">advances in software and increased access to inexpensive compute power means more and more engineers can use Multiphysics analysis to improve their design processes.</a><h2 dir="ltr" id="isPasted">About the sponsor: Altair</h2>Altair is a global technology company, which provides software and cloud solutions in the areas of simulation, high-performance computing (HPC), and artificial intelligence (AI). Altair enables organizations in nearly every industry to compete more effectively in a connected world while creating a more sustainable future. &nbsp;Wherever you are and whatever you&rsquo;re doing, Altair&rsquo;s solutions surround you &ndash; keeping you safer, more connected, and more productive. They can be found in big places and small &mdash; on highways, hospitals, and hockey rinks, in stadiums, skyscrapers, and subways, and in banks, bikes, and boats.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM3MTQwNTE5MzQ3LWxvZ28gYmFubmVyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">

Article #3 of our simulation series. Advanced simulation tools helped this German startup design a press machine that plays a role in reducing carbon emissions. 

Pressing For Change at Atna

Innovation in product-development is a demanding task. Engineering teams across all industries are continuously facing the challenge to create innovative and increasingly complex products while meeting all kinds of requirements such as target costs, time constraints, regulatory requirements, and improved product performance.&nbsp;In today&#39;s fast-moving world, these requirements are constantly evolving. Fortunately, there is a solution to overcome these engineering challenges, CAE (Computer Aided Engineering) tools. These tools facilitate computerized simulations that can solve all kinds of engineering challenges and help product developers achieve their design goals while reducing costs and time-to-market.&nbsp;<h2 dir="ltr" id="isPasted">Why use simulation?</h2>Simulation is not a new method. Thousands of engineers and companies have been using various simulation tools to improve their development processes and products for many years. However, for many others, simulation is not leveraged due to implementation costs and efforts or lack of human resources. These engineers and companies have not yet realized that CAE tools can help them develop innovative products while reducing costs and development cycles at the same time. This article demonstrates the benefits of simulation and virtual development processes using two real-life case studies.&nbsp;The value of a comprehensive simulation-driven design approach is made clear by showing how the modeling and prediction of part behavior can be produced more accurately, as model features and fidelity can be modified to fit the needs of a particular analysis. By importing CAD into CAE-centric analysis software, the user gains more control over the accuracy and speed of analysis.&nbsp;<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM2Mzc4MTE1MDY2LW1vZGVsIGFuYWx5c2lzLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">Image Caption: Modal Analysis with Altair Simsolid on the parameterized complete assembly. Image caption: Altair.&nbsp;</div><h2 dir="ltr" id="isPasted">Examples of a successful implementation of simulation-driven design</h2>There are countless examples of engineers seeing tangible results in their design process and quality after integrating simulation. Many designers who were using CAD integrated simulation features realized at a certain point that these native tools were not sufficient for what they wanted to achieve. Iconic bike manufacturer Brompton Bike is an excellent example of this.&nbsp;The Brompton team started with a CAD solution but at one point realized that this would not be sufficient for their needs. Jonathan Heath, Lead Mechanical Engineer Brompton Bicycle describes the evolution to using advanced simulation tools:<blockquote>&quot;The step we made was moving from an embedded FE system within CAD, which has huge limitations. It had a purpose. But we outgrew that purpose. And moving to a specialized simulation software package gives a more comprehensive FE system - greater flexibility - greater breadth. And that&#39;s opened up the mindset, not just of the design engineers, but of management and how we can use this tool on design problems we never really knew we had. We know where the failures are likely to be if we&#39;re going to see failures before we start the test cycle. And that improves the design robustness and allows us to move to the next development cycle quickly and with more understanding of the design.&quot;</blockquote><div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM2Mzc3OTY3MDY1LWJyb21wdG9uLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">Brompton uses specialized simulation software to test and develop new products. Image credit: Altair.&nbsp;</div>The use cases for a simulation-driven design process are not limited to the bike industry. Similar stories can be found from small startup companies to world-leading providers of passenger transport systems (skiing lifts) such as <a href="https://www.altair.com/resource/topology-optimization-improves-gondola-lift-station-building" rel="noopener noreferrer" target="_blank">Doppelmayr</a>. With the application of specialized simulation tools to their development processes, the Doppelmayr engineers were able to increase the lifetime of a seam weld while reducing the length of each component&#39;s weld seam by 3.5 meters. In addition to that Doppelmayr also reduced manufacturing time and costs by approximately 10% for the new design.&nbsp;Other examples come from industrial machinery, heavy equipment, or <a href="https://www.altair.com/resource/nolato-autoinjector" target="_blank">medical devices</a>. What they all have in common, is that at a certain point in time they had to start applying simulation into their processes, to get products faster to market, increase product quality or performance, or make their products lighter.&nbsp;As shown in the examples above, increasing innovation, product performance, and customer satisfaction can go hand in hand with reducing development time, manufacturing risks, and overall development costs. CAE tools offer multiple opportunities to drive the development of innovative products from the first concept up to series production.&nbsp;Linking test, design, and simulation and the implementation of a simulation-driven design process right from the start of a project can tremendously streamline the entire process and thus foster innovation - providing all industries and companies relying on simulation with the most valuable assets of all: the competitive edge to stay ahead in innovative product development and satisfied customers.<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM2Mzc4MzI3MzQwLXN0cnVjdHVyZWFsIGFuYWx5c2lzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">Structural analysis with Altair SimSolid&trade;. Image credit: Altair</div><hr>Whether you are completely new to simulation or looking to expand your capabilities, the free one-day virtual event, Don&#39;t be Late to Simulate, on November 30 is a great way to expand your knowledge. Learn more about using simulation for more efficient and effective product design, hear from startups who are using simulation in their design process and take part in hands-on workshops. <a href="https://hubs.ly/H0-wpBD0" rel="noopener noreferrer" target="_blank">Learn more about the event here.</a><hr><h2 dir="ltr" id="isPasted">How to apply simulation efficiently with Altair</h2><a href="https://www.altair.com/" rel="noopener noreferrer" target="_blank">Altair</a> is one of the leading simulation software providers, they offer solutions to help engineers make the first step to incorporating simulation into their design process.Altair Inspire&trade; provides intuitive surface modeling and geometry modification tools to help users prepare models for analysis at the fidelity that best suits the analysis detail and solver performance needed at that stage of the development process. This ensures that iteration and comparative studies are possible in early-stage design while offering the flexibility to model at higher fidelity for performance validation and detailed physics assessments.Altair SimSolid&trade;, is a solver available within the Altair Inspire product. Users can import intricate CAD geometries and assemblies, including connections, contacts, welds, detailed dimensions and angles, and more without model simplification or modification. This solver produces results in seconds to minutes, enabling multiple concepts to be assessed in less time than one typical CAD-based simulation run, shortening the design cycle while increasing the insight into the product&#39;s behavior.&nbsp;Altair SimLab&trade; offers more detailed multiphysics analyses, including structural, thermal, and fluid dynamics. It has an intuitive user interface that enables geometry to be imported and updated via the bi-directional CAD coupling.&nbsp;All of these tools are straightforward to learn and can be implemented in whatever your design and development process currently is. Interfacing with all common CAD and CAE tools, Altair offers also a flexible licensing scheme so you can step up your use of simulation without unnecessary investment.&nbsp;This is the first of&nbsp;<a href="https://www.wevolver.com/profile/altair" rel="noopener noreferrer" target="_blank">five articles&nbsp;</a>in a series about simulation tools sponsored by Altair. Future articles will cover case studies on using simulation in product design, cover workshops on how to get started with advanced simulation software, and explore the applications of multiphysics simulation.&nbsp;Altair is hosting the free virtual global event, <a href="https://hubs.ly/H0-wpBD0" rel="noopener noreferrer" target="_blank">Don&#39;t Be Late to Simulate</a> on November 30, 2021: 2:00 p.m. (Paris) and at 8:00 a.m. (New York).&nbsp;If you are interested in moving from CAD-based simulation to a more robust solution or if you have looking to expand your capabilities, this free to attend virtual event offers a mix of keynotes, case studies, and workshops to help you to be more efficient and effective in how you develop new products.<a href="https://hubs.ly/H0-wpBD0" rel="noopener noreferrer" target="_blank">Register to attend here.</a>Article #2 <a href="https://www.wevolver.com/article/why-cad-based-simulation-can-become-a-game-of-cat-and-mouse" rel="noopener noreferrer" target="_blank">demonstrates w</a><a href="https://www.wevolver.com/article/why-cad-based-simulation-can-become-a-game-of-cat-and-mouse" rel="noopener noreferrer" target="_blank">hy CAD-based Simulation Can Become a Game of Cat and Mouse.</a>Article #3 is for <a href="https://www.wevolver.com/article/pressing-for-change-at-atna" rel="noopener noreferrer" target="_blank">advanced simulation tools that helped this German startup design a press machine that plays a role in reducing carbon emissions.</a>Article #4 <a href="https://www.wevolver.com/article/simulation-driven-design-for-product-engineers" rel="noopener noreferrer" target="_blank">previews a workshop that will take place at the Don&rsquo;t be Late to Simulate event on November 30.</a>Article #5 speaks for the&nbsp;<a href="https://www.wevolver.com/article/an-engineers-guide-to-multiphysics-modeling-real-world-behaviour-and-predicting-performance" rel="noopener noreferrer" target="_blank">advances in software and increased access to inexpensive compute power means more and more engineers can use Multiphysics analysis to improve their design processes.</a><h2 dir="ltr">About the sponsor: Altair</h2>Altair is a global technology company, which provides software and cloud solutions in the areas of simulation, high-performance computing (HPC), and artificial intelligence (AI). Altair enables organizations in nearly every industry to compete more effectively in a connected world while creating a more sustainable future. &nbsp;Wherever you are and whatever you&rsquo;re doing, Altair&rsquo;s solutions surround you &ndash; keeping you safer, more connected, and more productive. They can be found in big places and small &mdash; on highways, hospitals, and hockey rinks, in stadiums, skyscrapers, and subways, and in banks, bikes, and boats.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM2Mzg2OTM0MDkyLWxvZ28gYmFubmVyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">

Article #1 of our simulation series. Simulation tools improve the development process, enabling engineers to deliver better products in less time.

Simulation-Driven Design: The Secret to Better Products in Less Time

Together with <a href="https://www.wevolver.com/profile/ansys" id="isPasted" target="_blank">Ansys</a>, a developer of simulation software, we have created a series of content about the technologies that make sustainable transportation possible. This article provides a summary of the series with links to read more.&nbsp;<h2>Introduction</h2>Without simulation, we would not be at the current status of eclectic and autonomous cars. Simulation is a key part of the major technologies that can help to lower the environmental footprint of transport.&nbsp;Among these are:<ul><li dir="ltr">Battery technology</li><li dir="ltr"><a href="https://www.wevolver.com/article/real-time-generative-design-for-transportation-lightweighting" rel="noopener noreferrer" target="_blank">3D Printing to reduce weight and carbon footprint of electric vehicles</a></li><li dir="ltr"><a href="https://www.wevolver.com/article/digital-twins-bridge-the-gap-between-product-development-and-product-operations" rel="noopener noreferrer" target="_blank">Digital Twins</a></li></ul>Further, it explores ways to increase the efficiency of internal combustion engineer vehicles until they phase out through the use of synthetic fuels and camless engine technology.&nbsp;Simulation plays a critical role in each of these steps towards decarbonization. Using simulations has been shown to reduce the development time required to bring a car to market by 50%. It is also linked to a 12% improvement in energy efficiency and power density, boosting the environmental impact of electric vehicles. For example, simulation is a useful tool for developing the electric systems and power train in electric vehicles. It can help increase the power density and lifetime of power electronics while optimizing the electrochemistry of the battery and ensuring the safety of the system.&nbsp;<div class="fr-img-space-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1635255213240-lightyear-one-solar-simulation-social.webp" style="width: 7888px;" class="fr-fic fr-dib">Lightyear One was developed using multiphysics simulation software.</div><h3 dir="ltr">Competition drives innovation</h3>The Indy Autonomous Challenge was a year-long event that saw university teams compete against each other to develop the best autonomous driving system. The challenge finished with a high-speed race at the Indianapolis Motor Speedway (IMS) with teams vying for 1 million dollars in prize money. The challenger provided a really important method for emerging engineers to develop technology outside of the corporate structure, experiment, share knowledge and ultimately make a significant contribution to the future of autonomous vehicles.&nbsp;The winner of the historic race was TUM <a href="https://www.indyautonomouschallenge.com/technical-university-of-munich" target="_blank">Autonomous Motorsport from the Technische Universität München</a> (TUM). T<a href="https://www.indyautonomouschallenge.com/rules-body" target="_blank">he IAC&nbsp;</a>race required each team to compete in a fastest lap competition that included an obstacle avoidance component. The winning team recorded the fastest 2-lap average speed of 135.944 on the famed IMS Oval.<iframe width="640" height="360" src="https://www.youtube.com/embed/YBpdUr1t7_o?&amp;wmode=opaque&amp;rel=0" frameborder="0" allowfullscreen="" class="fr-draggable"></iframe> The primary goal of the IAC was to advance technology that can speed the commercialization of fully autonomous vehicles and deployments of advanced driver-assistance systems (ADAS). These enhancements will lead to increased safety and performance in motorsports as well as all modes of commercial transportation.&nbsp;“The IAC is a test bed for developing autonomous technology and the brain power that goes into it,” says Tarun Tejpal, Ansys’ industry marketing director for transportation. “An autonomous race car is basically a supercomputer on wheels. The teams have to optimize that supercomputer and the only way you can do that is with Ansys simulation technology.” He notes that the hardware and software have been coming together over the last decade to bring autonomous driving closer to reality. “Now it’s just a matter of human ingenuity,” he says. “By putting these student teams in a competitive situation, they will exponentially innovate the autonomous technology that will eventually be used in commercial automobiles.”Essential for the teams to compete in the final event was participatio<a href="https://www.wevolver.com/article/the-indy-autonomous-challenge-simulation-race" rel="noopener noreferrer" target="_blank">n in the Simulation Race</a>. Here teams had to perform certain minimum requirements such as single la performance and the ability to overtake without crashing. The final was a 10-lap race won by <a href="https://pennsylvanianewstoday.com/polimove-wins-ansys-indy-autonomous-challenge-simulation-race-state/180619/" rel="noopener noreferrer" target="_blank">PoliMove</a>, who took home $100,000.&nbsp;<h2>Cities and systems simulated to herald new era of automotive</h2>As the way transportation changes so does the functionality and performance of cities and public spaces. By harnessing the Internet of Things (IoT) with the rapid connectivity of 5G (and beyond), cities are evolving to become smarter, cleaner, more efficient, and more habitable not just for humans but for future transportation too. Ensuring that emerging technologies such as alternative fuel cars work within the current envelope and limit of our cities presents immense challenges to architects, engineers, urban planners, and automakers.<div class="fr-img-space-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1635255353357-Wind-in-city-a%C3%A9raulics-study-cfd-simulation.jpg" style="width: 788px;" class="fr-fic fr-dib">Virtual 3D city models compose particularly an important concept in 3D geoinformation systems. They can be used in urban planning, defining of traffic routes, disaster management, etc. Image credit: Ansys</div>These challenges can be met by using simulation software in the design and testing of various city features, from the number and placement of EV charging stations to the placement of 5G towers for maximum effect and aesthetic.Simulating, testing, and iterating smart city solutions before implementation is key to a ‘smarter’ smart city future. Not only is simulation essential in a design and planning phase it can also be used through technologies such as digital twins to monitor and maintain systems in a &nbsp;predictive manner.&nbsp;<h2 dir="ltr">Summary</h2>Reducing emissions and decarbonization will only be achieved through innovation. This innovation will come largely from the ability to test and design rapidly with exponential pace. Discover more about the role of simulation in cutting-edge technology at the Ansys profile.&nbsp;<h2 id="isPasted">About the sponsor: Ansys</h2>Ansys provides engineering simulation software used to predict how product designs will behave in real-world environments. Founded in 1970, Ansys employs more than 4,400 professionals, many of whom are expert M.S. and Ph.D.-level engineers in finite element analysis, computational fluid dynamics, electronics, semiconductors, embedded software, and design optimization.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjM1MjU0MzQyNjc1LUFuc3lzIGJhbm5lciBpbWFnZS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 788px;" class="fr-fic fr-dib">

Simulation Software

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7 Design Tips for Structural Optimization & Lightweighting

Simulation-driven design for product engineers

Pressing For Change at Atna

Simulation-Driven Design: The Secret to Better Products in Less Time

The role of simulation in decarbonizing transportation

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