Simulation Design for Manufacturing

Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes. Users can validate designs early in the manufacturing process with the simplicity and affordability of the simulation software, and use advanced optimization technology with specific manufacturing constraints to design better, more efficient products.

Altair’s extensive applications for product manufacturability covers numerous industry sectors, including automotive, aerospace and defense, electronics, pharmaceuticals, technology, manufacturing, and heavy industry.

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Simulation-Driven Design for Manufacturing (SDfM) Experiences

Discover the most recent trends in SDfM in this report.

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Altair 3D printing to reduce the manufacturing and simulation cost

3D Printing

Looking to exploit the benefits of engineering with lattice structures? Altair® Inspire™ enables teams to cut product development and additive manufacturing costs by reducing material usage, print times, and post-processing. Altair® Inspire™ Print3D provides a fast, accurate toolset for the design and process simulation of metal binder jetting and powder bed fusion type processes. Independent of the printer type, designers can easily explore and modify critical process variables to evaluate design performance. Further manufacturing process analyses can be performed via premier third-party tools available through the Altair Partner Alliance (APA).

Altair Inspire mold is a modern manufacturing and simulation software

Injection Molding

Altair® Inspire™ Mold is a modern, integrated software to streamline design for manufacturing (DfM) of injection molded components. Fast, accurate simulations answer the question "will it fill?" for even large, complex parts in under an hour. Identify potential manufacturing defects early in the development process and make better, more informed design decisions. Leap from manufacturing "know how" to "know why," deliver superior products, reduce scrap, and slash tooling rework costs.

It includes a fast-casting process, manufacturing, and simulation software.


Altair’s offering includes a fast casting process simulation software that allows the user to enhance and optimize their manufactured components in order to avoid typical casting defects. Altair® Inspire™ Cast is a simulation environment focused on creating high-quality components with increased profitability through a highly intuitive user experience catering to beginners and experts alike. Additional casting simulations products are accessible through the APA.

Altair Inspire Form is a sheet metal forming simulation software

Metal Forming

Altair® Inspire™ Form is a sheet metal forming simulation software that enables users to optimize their products for manufacturing, with the consideration of early formability, material utilization, and cost. Cold and hot sheet metal forming, tube bending, hydroforming, and composite forming are supported. Run early manufacturing feasibility analysis within seconds or perform advanced process validation, optimization, and virtual try-outs leveraging an accurate, highly-scalable solution.

Altair Inspire Extrude is a manufacturing and simulation solution


Every extrusion company is looking to eliminate costly prototypes and reduce redesign cycles. With Altair, advanced physics simulations are now accessible to organizations of all sizes. Altair® Inspire™ Extrude is a simulation solution for both metal and polymer extrusion. It helps achieve productivity gains by reducing product development costs and improving extrusion quality, increasing production yield. Lower scrap rates can be achieved by exploring process improvements on a virtual press.

Altair EDEM enables companies to accurately simulate the behaviour of particles.

Process Manufacturing

Altair® EDEM™ software is used by top-tier process manufacturing companies worldwide in the pharmaceutical, chemical, consumer packaged goods, and asphalt industries to optimize the performance of equipment handling and processing bulk solids. EDEM enables companies to accurately simulate and analyze the behavior of particles, from powders to tablets, providing key information on processes otherwise difficult or sometimes impossible to measure.

Altair Inspire Polyfoam provides a modern integrated approach to streamline DfM

Polyurethane Foaming

Rigid and flexible polyurethane foams, also known as cellular or expanded polymers, surround us. Their important attributes like lightweight, adaptable strength per unit weight, and insulation characteristics, as well as their inherently high sustainability make them attractive for an increasingly wide range of industrial and household applications.

Altair® Inspire™ PolyFoam provides a modern integrated approach to streamline DfM of flexible molded foam components and rigid foam panels.

It is a solution that accelerates the development of tightly packaged electronic products.

Circuit Boards and Electronics

Run DfM checks early in the development cycle with Altair® Pollex™. Increase efficiency of printed circuit board (PCB) fabrication, assembly, and end-of-line testing, with the export of fabricating, mounting, paneling, and testing data to production line machinery.

PollEx is not just a PCB verification tool, it is solution that accelerates the development of today’s smart, connected, and tightly packaged electronic products.

Altair SimLab includes a very accurate simulation of fiber orientation


Composite material behavior is defined as components are manufactured. Develop and simulate multiscale heterogeneous material models with Altair® Multiscale Designer™, while assuring manufacturability with draping and forming simulation for sandwich and multilayered laminates combining Altair and APA third-party products.

For engineered plastics, Altair® SimLab® includes a very accurate simulation of fiber orientation during filling and analysis of the structural performance of the complete assembly.

Altair® Material Data Center™, a high-fidelity material database for simulation

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APA Solutions for manufacturing and simulation

Altair Partner Alliance (APA) Solutions for Manufacturing

Further enhance your manufacturing with partner products from the APA. APA manufacturing solutions feature integration with Altair workflows to help improve the product development lifecycle.

  • For metal additive manufacturing, Amphyon by Oqton is a powerful tool for simulation-based job preparation that enhances part accuracy and minimizes failure rates.
  • Complement Altair’s topology optimization with Materialise’s 3-matic software that works on an STL level to allow users to modify designs, remesh, create 3D textures, and more.
  • AFDEX by MFRC is the ideal tool to meet your metal forming simulation needs and better predict metal forming loads.
  • Good Guys’ Index (GGI) by NovaCast calculates the carbon dioxide (CO2) emissions generated from the casting process when producing a specific casting part.

These tools and more available are available through your Altair Units license.

More APA Solutions

Featured Resources

Mass Optimization of a 3D Printed, Small Series Prototype e-Drive Housing at Porsche

In his presentation, Sebastian Wachter of Porsche takes us through an exciting project where topology optimisation technologies were combined with 3D printing to create a highly innovative engine-gearbox housing that is 10% lighter than the existing component and twice as stiff.

Conference Presentations

Guide to Injection Molding

Nowadays to remain competitive, the need to constantly improve injection molding processes can benefit from modern technological advancements that simulation offers to overcome known disadvantages. With the aid of sophisticated computer-based tools, virtual product design enables engineers to look at and gain a better understanding of the entire process – from first idea through to seeing how the top clips on and stays on - all before taking the first step towards the factory floor. This e-Guide includes illustrations from the collaborative product design study Altair developed with Nolato for “Nolava”, a battery-powered medical electro-mechanical auto injector. These devices need to be robust and reliable because they are used every day around the world by people needing life-saving medication that is administered in the home by non-medically trained staff.

Validate and Optimize Manufacturability of Concept Design

Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for several subtractive and additive manufacturing processes, including casting, injection molding, metal forming, extrusion, and 3d-printing. In this session, users will learn how to validate designs early in the manufacturing process with the simplicity and affordability of the Inspire family of products.


Reinventing Rail Mobility through Digital Transformation, by Alstom

Introducing HealthHub, Alstom's smart asset monitoring for optimized life-cycle cost. Its purpose is to gather and consolidate data in a single location, whereby applying business rules supports maintenance activities and asset operation.

Future.Industry 2021
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