Case Study: Gestamp Automocion achieves 93% reduction in weld distortion with Altair HyperStudy

Reducing Weld Distortion by 93% with HyperStudy

Gestamp Automocion, a global designer and manufacturer of automotive chassis and suspension components, faced significant weld distortion on the BMW MINI front subframe tower that led to costly geometry rework. To accurately predict distortion and optimise both weld placement and welding sequence, Gestamp used Altair’s HyperStudy within the HyperWorks CAE platform.

Altair applied HyperStudy-driven DOE and multi-objective optimisation (ARSM and HMMO) to fix critical welds, remove or reassign others, and optimise welding sequence while constraining stiffness. The work produced a 56% reduction in predicted top-of-tower distortion from weld removal optimisation and a 93% reduction from sequencing, maintained equivalent stiffness with improved peak-stress performance, and delivered measurable time and cost savings using Altair’s HyperStudy.

Gestamp Automocion

Adrian Chapple

Analysis Supervisor