Case Study: BASF achieves 45% lighter, cost-neutral seat pan with Altair simulation and optimization

BASF - Customer Case Study

BASF, a global chemical supplier to the automotive industry, faced the industry-wide challenge of lightweighting to meet stricter fuel-economy and CO2 regulations while controlling development time and cost. The company leveraged virtual simulation and optimization techniques and its Ultramid polyamide specialties to rethink a conventional stamped-steel seat pan, a project that was later recognized by Altair through the inaugural Altair Enlighten Award—an award that highlights innovations using optimization software and material substitution.

To solve the challenge, BASF and GM Opel developed the world’s first production thermoplastic composite seat pan using continuous fiber-reinforced laminates with two special Ultramid grades, combined with in-mold forming, thermoplastic IR heating, over-molding and robotic handling. The approach—driven by virtual simulation and material optimization—cut the seat pan weight by 45% (from 1.5 kg to 0.8 kg), saved 1.6 kg per vehicle overall, remained cost-neutral, reduced packaging space, and earned BASF the Altair Enlighten Award for measurable lightweighting impact.

BASF

Martin Jung

Senior Vice President of Global Research for Structural Materials