Case Study: KTM Technologies achieves 21% mass reduction and 150–200 RPM increase with Altair HyperWorks

Reduction of Moving Masses – Streamlined Design for Improved Engine Performance

KTM Technologies needed a lighter, stiffer rocker arm for the KTM 450 Factory Edition to extend the engine rpm range without compromising durability. As an Altair customer, KTM Technologies leveraged Altair HyperWorks—using Altair HyperMesh for preprocessing, Altair OptiStruct for topology optimization and nonlinear FEA, and Altair HyperView for postprocessing—to redesign the component while accounting for forging manufacturing constraints.

Using Altair’s tools, KTM Technologies performed topology optimization and detailed structural analyses to produce a more compact, mass-centered rocker arm with improved contact distribution. The Altair-driven solution reduced component mass by 21% and inertia by 15%, increased stiffness by 14%, improved durability, and extended the engine’s rotational speed by about 150–200 rpm.

KTM Technologies

David Marschall

Group Leader Structure & Optimization, Department Simulation