Case Study: University of Salento achieves 15% waste reduction and simulation runtimes cut from hours to seconds with Altair's digital twin

University of Salento - Customer Case Study

The University of Salento faced the challenge of better understanding and controlling sheet‑metal forming processes—accounting for material properties (stress, strain, elasticity) and equipment conditions (pad force, die friction)—to improve product quality and cut production waste. They turned to Altair for a digital twin solution that could combine simulation and real sensor data to monitor and predict forming performance in real time.

Altair implemented a comprehensive digital twin using Altair Inspire Form for FEA, HyperStudy for DoE, romAI for reduced‑order models and ML, Altair Activate for real‑time simulation, and Panopticon for dashboarding. By fusing simulated and accelerometer/AutoGrid sensor data, Altair enabled operators to detect deviations and apply corrections, reducing production waste by more than 15% and shrinking simulation runtimes from hours to seconds while enabling immediate delivery of axle attachment brackets.

University of Salento

Antonio Del Prete

Associate Professor, Manufacturing Technologies and Production Systems