Case Study: VTT achieves a lighter, smaller and higher-performing 3D-printed valve block with Altair's OptiStruct

Optimized Design for 3D Printed Valve Block Sheds Weight, Size and Gains Improved Performance

VTT (Technical Research Centre of Finland) needed to demonstrate how additive manufacturing could produce a smaller, lighter, and better-performing valve block for Nurmi Cylinders by redesigning internal channels and meeting SLM printing constraints. To tackle the challenge VTT used Altair’s HyperWorks CAE suite—specifically OptiStruct and OSSmooth—and accessed Materialise 3-matic via the Altair Partner Alliance to drive topology optimization and printable geometry preparation.

Using OptiStruct for topology optimization, OSSmooth for shape generation, and 3-matic to smooth and ready the mesh, Altair’s tools enabled a manufacturable, optimized design that met all stress and strength requirements, improved internal fluid flow, and reduced material waste. The new 3D‑printed valve block weighs under 600 g versus over 2.5 kg traditionally (a 76% weight reduction), with a smaller overall size and a set of SLM design rules established for future production.

VTT

Erin Komi

Research scientist