Case Study: Thales Alenia Space achieves 48% mass reduction and improved thermal performance with Altair

Maximizing the Potential of Additive Manufacturing with Design Optimization

Thales Alenia Space, a European aerospace manufacturer, wanted to evaluate how additive manufacturing (AM) combined with design optimization could reduce mass and improve thermal performance of a satellite filter bracket. After a search for expertise in optimization for aerospace, Thales Alenia Space selected Altair (Altair ProductDesign) to apply its HyperWorks toolset, including HyperMesh and the OptiStruct solver, to the problem.

Altair created a combined thermal–structural model, ran topology optimization with OptiStruct, and interpreted the organic topology into an additive-manufacturing‑ready CAD design; the new bracket cut mass by 48% (well above the 15–20% target), reduced thermal compliance, and maintained the original structural performance. Altair’s work demonstrated significant, measurable AM benefits and has led the teams to explore further enhancements such as lattice structures.

Thales Alenia Space

Angel Martinez Martin

Physical Design Manager