Case Study: Manz achieves automated, large‑volume, optimized CFRP production with Altair

Fully automated in a single process Optimization and manufacturing of CFRP components

Manz, a high‑tech engineering company, faced the challenge of making carbon fiber reinforced plastic (CFRP) parts economically viable for series production: complex geometries, largely manual processes, and the need to integrate load‑specific design into the newly developed Fiber Patch Preforming (FPP) manufacturing route. To address this, Manz partnered with Altair, using Altair’s HyperWorks/OptiStruct‑based three‑step composite optimization approach to automate and precede the FPP production workflow.

Altair built an automated optimization process (via Altair ProductDesign and HyperWorks tools) that feeds optimized laminate, patch orientation and process data directly into Manz’s FPP production machine; the pilot bicycle‑seat showed the optimized part met stiffness and safety targets while cutting weight by 30% versus the non‑optimized version and halving material waste (≈50% reduction). Altair’s solution also enabled much shorter cycles, easier machine programming, flexible product changeover and a pathway to large‑volume, automated CFRP production.

Manz