Steve McGugan, an award-winning industrial designer based in Denmark, faced the challenge of designing and modeling complex products using 3D modeling and design tools. With over 30 years of experience in various areas of product design, Steve needed a flexible and efficient 3D modeling software that could run on his Mac computer. His initial CAD-based platform of choice was a solid modeler, which he used for many years. However, about a decade ago, he found it was no longer flexible enough to meet his demands. The market was saturated with many Windows-based machines that he felt lacked aesthetics. He needed a solution that would not only meet his design needs but also align with his aesthetic preferences.

Amcor Rigid Plastics, a leading product supplier for various packaging segments, was facing challenges in maintaining a balance between packaging performance, environmental impact, and shelf appeal while keeping costs to a minimum. The company was under pressure to create more environmentally friendly products. Amcor was also looking for innovative and lightweight container designs that would be aesthetically pleasing and easy to handle for the consumer without compromising on quality, performance, or safety. The company was using Altair’s HyperWorks suite to create accurate finite element models of the concept designs from the CAD teams to assess their performance in the virtual world. However, they wanted to explore ways to accelerate the engineering and analysis tasks associated with the development of new packaging products. The virtual test process used to investigate the performance of new packaging designs under various loading and impact scenarios was consuming a large amount of the simulation team’s time.

HardMarque, a digital design and manufacturing studio, was faced with the challenge of reimagining the current piston design process. The goal was to manufacture a piston that was not only lighter than the current versions but also equally as strong. This was a significant challenge as it required a balance between weight reduction and strength maintenance, which is a critical factor in the performance and efficiency of automotive engines. The challenge also extended to the integration of the new design with additive manufacturing equipment, a process that required precision and compatibility with the chosen material, titanium.

SEGULA Technologies, an international engineering consultancy, faced a significant challenge in managing and monitoring a vast variety of commercial software licenses across the enterprise. As an engineering service provider, the company extensively uses computer-aided engineering (CAE), computer-aided design (CAD), and other commercial development software. The usage of these software tools varied, with some being used more frequently than others. However, all tools could be utilized on certain projects. The company needed to efficiently manage the peaks and valleys in software usage. Prior to implementing a solution, each business unit gauged its software requirements based on subjective data, leading to inefficiencies and potential overuse or underuse of licenses. The company sought a solution to optimize software usage, improve decisions on software renewal and acquisition, and better manage its IT budget.

Euro-Pro, a rapidly growing consumer products manufacturer, faced a challenge in its product development process. The company's product development was heavily reliant on physical prototype testing, which was time-consuming, costly, and often failed to provide a comprehensive understanding of product behavior during tests such as drops or impacts. The company wanted to increase the use of simulation to conduct more in-depth analysis of scenarios that were difficult or impossible to test physically, such as internal structural failures. The goal was to identify the root cause of product failures more accurately and provide better guidance to the engineering and product design teams. The company also aimed to test materials prior to their introduction on future generation products, with the hope of positively influencing the overall product portfolio direction in terms of market appeal, quality, reliability, and durability.

Scania, an international manufacturer of commercial vehicles and engines, was faced with the challenge of speeding up their design and development processes to produce lighter yet structurally and functionally efficient component designs. The automotive and commercial vehicle industries face many challenges when bringing a new product to market, including CO2 emission regulations and customer demands for more efficient vehicles. There is also high competition and pricing pressure in this market, forcing development teams to speed up their development process to achieve a shorter time to market. Scania's traditional process involved physical testing of prototypes, which led to many iteration loops between design and engineering departments, slowing down the development process.

Weld distortion is a significant issue in sheet steel product manufacture, especially in the automotive sector where tolerances are tight and complex high-performance components are the norm. The contraction caused by the welds cooling leads to distortion substantial enough to require additional processes to recapture the lost geometry. The sequence in which a part is welded largely affects the distortion of the part as the stiffness changes significantly depending upon which welds have already been executed. Gestamp Tallent Ltd, a world-class designer, developer, and manufacturer of cutting-edge automotive products, faced the challenge of accurately predicting weld distortion and optimizing the weld pattern to reduce it. They used the BMW MINI front subframe tower to demonstrate the weld distortion optimization approach. The tower is particularly susceptible to distortion due to its tall and thin dimensions.

Scania CV AB, a leading manufacturer of trucks and buses, was facing a challenge in accurately simulating squeak and rattle noise within a truck cabin. Squeak and rattle are two phenomena observed when two parts of an assembly are in relative motion due to a specific excitation load. In the automotive industry, these phenomena are studied to reduce cabin noise and improve ride quality and comfort for occupants. Historically, Scania’s Cabin Development Department did not perform this kind of simulation. The team had to rely on tolerance calculations and the choice of materials to reduce the risk of squeak and rattle. When first prototypes became available, iterations were made to fix and correct the final design to solve the noise issues. To reduce development time and cut down on iterative changes, a solution was needed that enabled a simulation-driven design process during the early stages of the cabin development cycle.

The challenge faced by Peter Macapia, the acclaimed architect behind LabDORA, was to change perceptions and convictions about how buildings could look and how they impact their environment. He sought to explore new frontiers in architectural design that simultaneously employed principles of architecture and engineering to produce entirely new insights and types of structures. Macapia's early work was based on research started in the 1960s and ‘70s in Japan, which had produced genetic-type algorithms for structural morphology. However, these early computational methods were primitive in their applicability by today’s standards. Macapia's perception of what was possible in his field changed significantly in 2010 when he was introduced to solidThinking Inspire while preparing a course for the Southern California Institute of Architecture (SCI-Arc) in Los Angeles.

Beta Epsilon, a design company specializing in racing cars and engineering services for automotive racing car providers and racing companies, faced a significant challenge in their development process. The company was responsible for a wide range of engineering tasks, including the meshing of parts and full vehicles, the FEA analysis of components, crash test simulation, optimization, and CFD analysis. In the design of a complete racing car, the engineers design and optimize every single part of the vehicle, simulate crash tests, simulate the CFD performance of the car, and push the test for FIA homologation before they or the customers start the production or build a prototype. To handle all of these tasks, Beta Epsilon needed a flexible and cost-efficient access to several CAE tools, some of which were used more frequently than others. However, due to the need to minimize development cost to offer their customers services at competitive prices, it was not feasible to invest in every single full license of each required tool.

Sundog Eyewear, a company committed to providing high-quality, innovative eyewear, faced the challenge of transitioning from a traditional 2D sketching process to a modern 3D modeling approach. The company needed to capture all the details of a production design, which was difficult with their existing 2D sketching process. The challenge was to find a tool that could help them visualize new products with realistic renderings, explore styling alternatives, and export the digital model. The tool also needed to be user-friendly and compatible with the Apple machines the company was familiar with. The Creative Director of Sundog Eyewear, Michal Hrk, who had years of experience in advertising and graphic design but no formal 3D modeling experience, was tasked with finding a solution.

Monash Motorsport, a student-run organization based at Monash University, has been consistently improving the performance of their race car since their first Australian SAE Student Racing competition in 2000. The team was facing new weight and performance challenges at the end of 2013. They aimed to develop faster, lighter, and more innovative race cars while keeping development time and costs under control. The evolution of 3D printing presented a new technology that could help them build even lighter cars. However, it also created new development challenges since the 3D printed components are only as good as their design. The team had to conduct an optimization to find the ideal material distribution in the components while taking into account the additional manufacturing constraints of the additive manufacturing technology.

MAHLE, a leading automotive systems supplier, faced a challenge in making their simulation results reporting consistent, thorough, and simpler to perform. The company conducts simulations for pistons, connecting rods, and pins, with pistons representing the majority of the group's work. The complexity of pistons, which must withstand high temperatures and huge inertia loads, introduces many variables into the design process. Six different engineers were creating slightly different reports, leading to variations in how the simulation story was being told to customers. The main question to be answered by the simulation is whether the piston will survive the engine test. These tests are quite expensive, and a pre-production piston needs to be tested before it is put into the engine to save physical testing costs and to enable more design iterations. The complexity of the evaluation is further increased by factors such as lightweight pistons, high-efficiency engines, highly-loaded four-cylinder engines, more variability, and different materials.

AAM, a global automotive supplier of driveline and drivetrain systems, was faced with the challenge of redesigning an automotive carrier with less weight and material usage than the original. The company, based in Detroit, Michigan, with offices in 13 different countries, specializes in the design and manufacturing of axles, chassis modules, driveshafts, transmission parts, and metal-formed products. The challenge was to create a lightweight design that would not only improve performance but also increase efficiency and fuel economy, which are particularly important in the automotive market.

Lockheed Martin, a global security and aerospace company, was faced with the challenge of managing high-performance computing (HPC) resources in multi-level security environments. The company configures systems for the government using Red Hat Enterprise Linux 6 cross-domain system (CDS) configurations for multi-level security (MLS). This configuration allows users and data at different security levels to share the same resources, which is particularly useful for the U.S. military and intelligence communities. However, because users at different security levels share the system, Lockheed Martin needed to deploy a resource scheduler capable of operating in an MLS Red Hat Enterprise Linux environment. This would enable the greatest flexibility in setting queue and job priorities, providing automated accounting information, and offering many other capabilities to help each user complete their runs in the appropriate time and with the appropriate priority.

Northwestern University's Integrated DEsign Automation Laboratory (IDEAL) was tasked with implementing a series of engineering design courses. The challenge was to incorporate computational design methods like modeling, simulation, and optimization, which are increasingly important in engineering design decision making. The process of creating and evaluating design alternatives often involves selecting a preferred design from many alternatives, a task that can range from difficult to impossible without the aid of computational methods. Therefore, it was crucial for engineering design students to be exposed to computational tools that would allow them to make sound design judgments when completing their design projects. The courses also needed to incorporate the application of design decision methods to industrial problems, providing engineering students with the experience needed to approach real-world design problems later in their careers.

The case study highlights three main challenges faced by companies in managing their Computer-Aided Engineering (CAE) data. The first challenge is the need for a central location where all CAE users can manage their data within an enterprise for easy retrieval and full traceability from CAD to CAE, and all versions of CAE to the final report. The second challenge is the lack of standardization in methods used by different engineers, the loss of knowledge when employees leave, and the manual nature of the processes. The third challenge is the difficulty in tracking versions of CAD and CAE models and distributing project data globally, especially for companies with multiple development organizations in different geographic locations.

Stanley Black & Decker (SBD), a global provider of hand tools, power tools, and related accessories, was seeking ways to maintain a competitive edge and bring better-performing products to market faster. The company was particularly interested in optimizing the hammer mechanism design for their top-selling rotary hammers and knew they needed a computer-aided engineering (CAE)-based approach. However, the CAE-based optimization they had been using had a runtime of about three weeks, which was not sufficient to stay competitive. SBD aimed to reduce this runtime to one weekend. The team realized they needed more computational power to drive desired performance improvements, but they were concerned about the cost of high-performance computing (HPC) hardware/cores, the effort to maintain and support a complex HPC system, and the ability to fully leverage this hardware with the necessary software licenses to keep utilization high.

DSM Engineering Plastics, a global provider of high-performance plastics, faced a challenge in the LED lighting applications sector. The heat sinks used in these applications, primarily made of aluminum, were responsible for dissipating heat generated by LEDs to the environment. However, aluminum, despite being a good heat conductor, had limitations such as high costs related to machining die-cast parts, limited design freedom, recyclability issues, and weight. DSM sought to provide a plastic-based solution for heat sinks to overcome these issues. To find an optimal design for the heat sink made of polymer material and predict its thermal performance, DSM needed to model natural convection and radiation cooling, the mechanisms by which LED heat sinks dissipate heat to the environment. The challenge was to find a tool that could accurately simulate these processes and provide reliable results.

Airbus, one of the largest aircraft manufacturers, has always been keen on weight saving as it directly impacts fuel consumption, cost, and carbon emissions. To further explore advanced manufacturing technologies, Airbus set up APWorks in 2013, a subsidiary dedicated to design, materials, and 3D printing. However, due to the confidential nature of customer projects, APWorks found it challenging to tangibly showcase the possibilities of parts designed specifically for Additive Layer Manufacturing (ALM). They needed a project that would allow them to demonstrate the potential of ALM, and decided on creating an electric motorcycle. The challenge was to design and produce a motorcycle that was significantly lighter than traditional models, while maintaining strength and durability.

Germany's largest independent engineering partner to the global automotive industry, EDAG, was seeking innovative processes to streamline vehicle development, particularly in the area of lightweight design for both passenger and commercial vehicles. The automotive industry is faced with the challenge of increasing fuel efficiency and meeting legal requirements on emissions, while ensuring safety and competitive pricing. Traditional methods of manufacturing often require design proposals to be adapted to manufacturing constraints, which can limit the potential for lightweight design. In a recent project, EDAG engineers were tasked with developing and manufacturing affordable lightweight constructions of a commercial vehicle that could meet individual customer specifications without major changes in production facilities. This required a process that not only offered the best design approach but also incorporated the requirements of the selected manufacturing method.

Robot Bike Company (RBC), a UK-based startup, was established by aerospace engineers and mountain biking enthusiasts. They aimed to combine additive manufacturing technologies with carbon fiber to create the best bike frames possible. The challenge was to deliver a customizable, lightweight, high strength bike frame made from carbon fiber, a common material in the industry. The carbon fiber tubes and other components were to be joined by additively manufactured titanium 'nodes', customized to individual riders' specifications. Altair ProductDesign’s engineering team was tasked with optimizing these joints, including the head tube, seat post, and chain stay lugs, to ensure they were lightweight, durable, and suitable for the additive manufacturing process.

The challenge faced by DECKED, a company founded by entrepreneurs Lance Meller and Jake Peters, was to create an innovative, robust, and useful storage solution for pickup trucks. The storage system needed to be able to withstand a load of 2,000 lbs, fit into a wide range of pickup models including those from Ford, GM, Chrysler, Toyota, and Nissan, and be manufactured for a compelling retail target price. The main issue was that the large capacity of a pickup truck often came at the expense of storage. The loading area was typically a simple box with no ability to store smaller items safely or secure them from theft. This presented an opportunity in the marketplace for a well-built alternative.

The Laser Zentrum Nord (LZN) and the Technical University Hamburg-Harburg (TUHH) were seeking ways to improve the design and optimization methods for components made with laser additive manufacturing methods. The challenge was to develop structures that are strong yet light, similar to naturally occurring biological structures like bones. The research project, TiLight, aimed to combine innovative design methods with new manufacturing capabilities to economically manufacture lightweight components from the material TiAl6V4, a high-strength titanium alloy. The aerospace industry was the primary focus of the project, where lighter components could lead to higher load capacity or range for aircraft. A standard retaining element in aircraft, a bracket, was selected as a test object for the project.

M.TEC Engineering, a Germany-based engineering service provider, was facing the challenge of meeting growing customer demands for specialized development services across various sectors. As a company that offers a wide range of services including industrial design, mechanical design, material selection, calculation simulation, prototype development, testing, industrialization, tooling, and quality assurance, M.TEC needed flexible access to a variety of software tools. The company was also experiencing constant growth and was striving to become one of Germany's leading service providers for plastics and composite technologies. A specific use case highlighted was the optimization and redesign of a faulty expansion oil tank, which required a comprehensive re-simulation and re-design of the entire oil tank model.

SOGECLAIR aerospace, a major partner in engineering and prime contractor for the aerospace industry, was tasked with the development of a new flooring concept for aircraft cabins. The challenge was to create a lighter structure, adjustable panels for all types of aircraft, and ensure easier installation and maintenance. The aerospace industry has always been at the forefront of weight optimization and lightweight design, hence it was not surprising that aerospace also was one of the first industries to use alternative materials such as composites. The engineers had to consider conflicting issues such as weight, design, maximal dimensions, strength, stiffness etc. The use of optimization technology is the solution to combine all of these constrains with respect to an optimal composite layout. In this context SOGECLAIR aerospace investigates innovative materials and processes to integrate them in the design, analysis, and optimization.

The smartphone industry is one of the fastest evolving and most competitive sectors in the electronics industry. New models are developed every few months, and any reduction in time to market can significantly impact a manufacturer's profitability, positioning, and reputation. However, certain aspects of the development process, such as drop-test simulation, have remained time-consuming and resistant to acceleration. Drop-test simulation is a crucial element in ensuring the quality and robustness of a smartphone. Despite using computer simulation for virtual drop testing, LG Electronics (LGE) faced challenges in shortening the simulation time due to the large number of parts and assemblies in smartphones, the time-consuming geometry cleanup, simplification, and meshing, and the multitude of contact definitions that required many manual steps. Thorough testing involves a variety of drop and bending conditions, where analysis setup is time-intensive. Post-processing and generating reports also contributed to the overall time to achieve results. On average, drop-test simulation took one to two weeks to set up, conduct, and analyze, with modeling and post-processing representing 60 to 80 percent of the time invested.

Renault, one of Europe's largest automotive manufacturers, was faced with the challenge of developing a new, efficient, and lightweight vehicle powertrain. The company aimed to further decrease the weight and increase the performance of existing and in-development engines by redesigning key components to use a minimum amount of material. The challenge was compounded by the need to meet tighter regulations across Europe, US, and Asia, and a shift in consumer demand for more fuel-efficient vehicles. The company also wanted to use design optimization techniques from the start of the development process, rather than as a tactical tool to combat weight problems in the detailed design phase. However, the complexity and time-consuming nature of creating powertrain models posed a potential barrier to this approach.

Scuola Normale Superiore (SNS), a public institution of university education at the forefront of global research, has a mission to convert IT innovation into opportunities in computational science. The SNS Faculty of Science hosts several internationally recognized research groups in Biology, Chemistry, Physics and Mathematics, which are involved in theoretical and applied research in nearly every scientific field. To support state-of-the-art research investigations with a strong theoretical/computational background, SNS established DREAMSLab, a center dedicated to high-performance computing (HPC) and cutting-edge visualization and virtual reality techniques. The core of the DreamsHPC computational facility is a Dell cluster with over 2600 cores monitored in real time. However, given the complexity of the simulations running on the DreamsHPC cluster, it was necessary to carefully plan the software layer to be deployed on the infrastructure. The key requirements were overall ease of management of the already-present heterogeneous hardware, as well as significant simplification for the addition of new computing nodes in the existing structure and the distribution of computational programs on the nodes.

Panasonic Ecology Systems Co., Ltd. was faced with the challenge of making product drop tests more reliable. The company, which plays a key role in the sales of Indoor Air Quality (IAQ) products and solutions globally, understood the importance of evaluating designs through drop-testing before completion to reduce losses. However, the traditional methods of drop-testing were not providing the desired level of reliability. The company was already using RADIOSS, a leading structural analysis solver for highly non-linear problems under dynamic loadings such as impact analysis, as part of their computer-aided engineering tools. The challenge was to make effective use of these resources without the need for new investment, and apply this analysis to product development in other product fields.