Case Study: Schiebel achieves 50% weight reduction on the CAMCOPTER® S-100 with Altair solutions

Fly High with Optimization - Optimizing Camcopter® S-100 Design at Schiebel

Schiebel, the Vienna-based manufacturer of the CAMCOPTER® S-100, faced the challenge of reducing weight and improving range and durability for long-endurance missions while meeting airworthiness requirements (including EASA LUC) and exploiting in-house metal additive manufacturing. To tackle this, Schiebel worked with Altair using a suite of tools—topology optimization, Altair CFD, Altair MotionView/MotionSolve, Altair OptiStruct and APA tool Amphyon—alongside 3D printing to create certifiable, lightweight designs.

Altair implemented a multidisciplinary, simulation-driven workflow (topology optimization, structural and thermofluidic simulation, multibody dynamics, and AM process/thermal-stress simulation with Amphyon) to redesign engine and bracket components for additive manufacture. The result: up to 50% component weight reduction and ~50% increase in stiffness/strength, avoidance of print failures and lower printing costs, roughly 2 months faster time to market and about 15% cost savings, enabling Schiebel to deliver a lighter, certification-ready S-100 using Altair solutions.

Schiebel

Dominik Kohl

Head of Additive Manufacturing