Case Study: Viessmann achieves 20% stiffer, acoustically superior boiler covers and ~30% cost reduction with Altair OptiStruct

Improving Heating Boiler Acoustics at Viessmann OptiStruct for Bead Pattern Optimization

Viessmann, a leading German manufacturer of household and industrial heating technology, faced acoustical problems in a new gas-fired boiler: the cover needed greater stiffness to reduce noise without adding cost or complexity. Altair’s OptiStruct was used as the chosen vendor product to explore bead-pattern alternatives to adding parts, aiming for a lightweight, manufacturable solution that improved structural stiffness.

Altair implemented a two-step OptiStruct workflow—topography optimization to generate an initial bead layout (using pattern grouping and circular beads) followed by shape optimization of bead widths through integrated morphing—enabling rapid parameterization even without CAD. The Altair solution delivered a 20% increase in cover stiffness versus the alternative design and roughly 30% cost/assembly reduction (consolidating four parts into one); the optimized cover went into production on the Vitopend 200 series, producing an acoustically superior boiler.

Viessmann

Andreas Schubert

CAE Manager