Case Study: Hero MotoCorp achieves lighter, optimised footrest design with Hexagon Apex GD and Simufact Additive

Hero MotoCorp used Apex GD and Simufact Additive software to structurally optimise and validated the design of the pillion rider footrest of a two-wheeler for Additive manufacturing

Hero MotoCorp, the world's leading two-wheeler manufacturer, sought to optimize the weight and design of a pillion rider footrest for its Hero Xtreme 200S bike using additive manufacturing. The challenge was to create a lighter, structurally efficient, and aesthetically pleasing component by leveraging generative design while ensuring manufacturability and a high-quality surface finish.

Using Hexagon's Apex GD and Simufact Additive software, the team developed a structurally optimized design. The solution involved using a Polynurbed NURB concept and Simufact's Orientation Assist feature to achieve the desired results. Hexagon's technology enabled a 28% weight reduction, a 47.1% improvement in structural efficiency, and a final product with minimal surface deviation (1.4%) and a surface roughness within the target of 60 microns.

Hero MotoCorp