Case Study: ThyssenKrupp Elevator achieves up to 56% weight reduction in cable-less cabin design with Altair

Developing a Revolutionary Elevator System for Tall Buildings

ThyssenKrupp Elevator developed a cable-less, electromagnetic elevator concept (BackPack and SideGuide) to travel and move horizontally in very tall buildings, but the new system reduced available payload and required aggressive weight savings. ThyssenKrupp Elevator engaged Altair (via Altair ProductDesign) to apply simulation and optimization tools from the HyperWorks suite (including OptiStruct) to explore innovative material layouts and sandwich/carbon-fiber panel configurations.

Altair implemented a three-stage approach—topology optimization for the BackPack structure, sizing optimization of sandwich panels, and composite ply/layup studies for carbon fiber—turning topology results into manufacturable layouts. The work produced a BackPack cabin 42% under target weight (56% under with carbon-fiber walls) and a SideGuide 16% under target (33% with carbon fiber); both designs met performance targets and gave ThyssenKrupp Elevator the confidence to advance the BackPack for testing and prototyping. Altair’s optimization delivered clear, measurable mass savings and validated the electromagnetic concept.

ThyssenKrupp Elevator