Case Study: SINTAVIA achieves ~15% weight reduction and 3x fatigue life with Altair (solidThinking Inspire)

SINTAVIA - Customer Case Study

SINTAVIA, the global leader in independent metal additive manufacturing, set out to prove it could produce aerospace replacement brackets that match or exceed existing parts’ mechanical properties while reducing weight. To do this, the company partnered with Altair, using Altair’s solidThinking Inspire (and solidThinking Evolve) for generative design and optimization as part of a workflow that started with blue-light scanning of the original part and full-load condition definition.

Altair’s tools guided multiple topology-optimization iterations, and SINTAVIA refined the chosen geometry with PolyNURBS before producing the parts on an SLM 280 twin‑laser machine in Inconel 718 and completing heat treatment, EDM removal, HIP, and finishing. The Altair-enabled solution delivered measurable gains: roughly 15% weight reduction, 3× increase in fatigue life, and lower porosity compared with the original bracket.

SINTAVIA

Doug Hedges

President