Case Study: Alliant Techsystems achieves 1,000‑lb (≈50%) weight reduction in Orion Launch Abort Motor manifold with Altair OptiStruct simulation-driven optimization

Structural Optimization Helps Launch Space Payloads

Alliant Techsystems (ATK) faced a critical mass and structural challenge on NASA’s Orion Launch Abort Motor nozzle manifold: the original steel manifold weighed ~2,000 lbs and needed to meet a flight-weight target while surviving complex operational and proof-test loads without compromising seal integrity or deflection limits. To achieve this, ATK turned to Altair and its OptiStruct simulation/optimization software to drive a simulation-led redesign of the manifold geometry and validate behavior under flight and test conditions.

Using Altair OptiStruct’s topology and free-shape optimization, ATK optimized the manifold outer profile against operational and proof-test loading (informed by CFD) while constraining stresses and displacements. The Altair-driven approach automated iterations that previously took months, cutting design time by about 30% and reducing the manifold weight to roughly 1,070 lbs (from the steel baseline and below the 1,300 lb target) while keeping maximum stresses within limits. Altair’s solution enabled the lighter, flight-capable manifold needed for the Orion program.

Alliant Techsystems

Blaine E. Phipps

Senior Structural Engineer