Case Study: CEC Systems achieves weight reduction and production optimisation of COLLAPSECON with Altair OptiStruct

Optimisation of a Collapsible Economic Container “COLLAPSECON"

CEC Systems developed the COLLAPSECON® C-400, a 40-foot semi‑automated collapsible intermodal container that stacks 4:1, but their prototype was nearly three times heavier than a standard container due to added moving parts and over‑engineering to meet ISO standards—raising weight, cost and manufacturability concerns. To address this, CEC Systems (with SIMTech) used Altair’s HyperWorks platform, notably Altair OptiStruct and HyperMesh, to identify critical load cases and drive design optimisation.

Using Altair HyperWorks/Altair OptiStruct, the team created finite‑element models, ran size, topology and shape optimisations, buckling and damage‑tolerance analyses, and redesigned hinges and corrugation patterns. Altair’s tools exposed over‑engineered components and enabled targeted changes—including a 2 mm reduction in Corten floor saving ~750 kg, thinner walls/roof, and lighter hinge steels—yielding an estimated ~30% weight reduction across key sections while cutting material use, manufacturing complexity and meeting required load performance.

CEC Systems

Nicholas Press

Managing Director & CEO