Case Study: BASF achieves optimized, safer plastic part designs with Altair OptiStruct (HyperWorks)

HyperWorks, especially OptiStruct is one of the central tools supporting the CAE efforts of BASF Engineering Plastics

BASF, through its Engineering Plastics Application Development Engineering Group, needed new virtual CAE concepts to make advanced materials practical for customers — especially methods to define optimal part geometry early and refine dimensions later. To meet this challenge they used Altair’s HyperWorks suite, notably OptiStruct for topology optimisation and HyperStudy-supported parameter/morphing workflows.

Altair implemented OptiStruct as the initial topology‑optimization tool with HyperStudy for parameter optimisation, integrating mathematical part optimisation into BASF’s CAE process. The Altair-driven workflow produced optimized FE designs and a prototype lower bumper stiffener (LBS) that fulfilled pedestrian protection requirements, demonstrating that Altair’s tools close a key gap in virtual part development and deliver requirements‑compliant parts.

BASF

Andreas Wüst

CAE Methods and Structural Parts, Engineering Plastics