Case Study: Bremar Automotion accelerates roll cage design and FIA/CAMS certification with Altair RADIOSS

Simulation Speeds Roll Cage Design

Bremar Automotion, a Melbourne-based engineering firm specializing in roll cage validation and design optimization, needed to rapidly develop and certify safe, regulation‑compliant roll cages for motorsport customers. To meet strict FIA/CAMS requirements — including destructive physical tests with loads around 10T and beyond 20T and maximum displacements of 50 mm — Bremar required accurate finite‑element modelling, quick iteration for different materials and tube sizes, and traceable documentation for governing bodies. Bremar partnered with Altair and used the Altair HyperWorks suite (including HyperMesh, RADIOSS, OptiStruct, MotionView/MotionSolve, HyperWorks Virtual Wind Tunnel and AcuSolve) to address these challenges.

Using Altair tools, Bremar implemented detailed 2D shell meshing, nonlinear crash and structural analyses with Altair RADIOSS, and automated parametric CAD driven by customer spreadsheets to speed iterations. The FEA results closely matched destructive physical tests, enabling Bremar to secure FIA/CAMS accreditation (listed on FIA Technical List No. 35) and certify roll cages for commercial use; the Altair environment also reduced software overhead by providing a single licensing ecosystem. The work delivered measurable confidence (validated against the specified 10T–20T load cases and 50 mm displacement), more accurate joint behavior prediction, faster assessments and lighter, optimized cage designs while lowering development time and cost.

Bremar Automotion

Brett Longhurst

Owner and Managing Director