Case Study: Gestamp Automocion achieves lower mass and greater durability for rear-twist-beam suspension with Altair HyperWorks (OptiStruct & HyperStudy)

Minimising Mass and Increasing Durability of a Vehicle Suspension System Using HyperStudy & OptiStruct

Gestamp Automocion, a global chassis component supplier, needed to reduce mass and increase durability of a rear twist beam (RTB) suspension system while meeting kinematics and compliance (K&C) targets like roll stiffness and roll steer. Altair was engaged to apply its HyperWorks tools—notably HyperMesh, HyperStudy and OptiStruct—and to develop a custom “RTB Toolbox” to eliminate the initial trial-and-error design loop and accelerate concept generation.

Altair implemented the RTB Toolbox inside HyperMesh, used HyperStudy-driven DOE to understand sensitivities, and applied OptiStruct shape and gauge optimisation (including reinforcer length and torsion-element tuning) to produce CAD-ready designs that met durability and K&C constraints. The result was a measurable reduction in initial design lead time and the generation of competitive low-cost, low-mass RTB variants that preserved fatigue life and performance, enabling Gestamp Automocion to react faster and deliver optimized suspension components.

Gestamp Automocion

Andrew Charlesworth

Design Analyst