Case Study: Re-Loc achieves up to 55% material reduction and halved production costs with Altair ProductDesign

Minimizing Material Use for an Innovative New Building Product

Re-Loc, a UK construction-product developer, faced a cost challenge: its clip for holding steel reinforcement bars inside concrete block cavities worked functionally but was too expensive for high-volume production. Re-Loc enlisted Altair (via Altair ProductDesign) to reduce material use and bring the design to a production-ready prototype while retaining required stiffness, durability and ease of installation.

Altair applied its HyperWorks suite (HyperMesh, OptiStruct) to run dynamic simulations and topology optimization, iteratively converting results into refined CAD designs and material choices. The optimized Re-Loc clips use 45–55% less material, halved production costs, improved stiffness and fit, and added stackability for storage—demonstrating Altair’s role in turning the concept into a manufacturable, high-performance product.

Re-Loc

Robin Holthusen

Owner