Case Study: DT HiLoad reduces tray weight 50% and increases payload capacity with Dassault Systemes' Abaqus FEA

DT Hiload - Customer Case Study

DT Hiload, a leading manufacturer of custom dump truck trays for mining, needed to design lightweight trays that deliver a continuous transition of stiffness and withstand highly variable loads, impacts and fatigue in harsh mining conditions. To address this challenge DT Hiload adopted Dassault Systemes’ SIMULIA Abaqus FEA on the 3DEXPERIENCE platform to simulate tray flexibility, joints, transverse beams and extreme load cases before physical testing.

Using Dassault Systemes’ Abaqus, DT Hiload ran nonlinear, realistic simulations (validated against strain‑gauge tests) to optimize tray geometry and support members. The solution enabled the Hercules Phase X design to reduce tray weight by up to 50%, lowering fuel costs and fatigue while increasing payload capacity—allowing customers to move more material with fewer trucks and accelerating ROI.

DT Hiload

Ray Sun

Senior Engineer