Altair Case Studies Innovative Sit-Ski Development through Composite Technology at National Composites Centre

	Innovative Sit-Ski Development through Composite Technology at National Composites Centre Altair

Innovative Sit-Ski Development through Composite Technology at National Composites Centre

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Equipment & Machinery Plastics
Applicable Functions	Facility Management Product Research & Development
Use Cases	Manufacturing Process Simulation Virtual Reality
Services	System Integration
Challenge	The National Composites Centre (NCC), a non-profit UK facility, was tasked with the development of an advanced technology demonstrator, a Sit-ski, using composite materials. The Sit-ski, a device used for sports on mountain slopes by individuals with lower extremity limitations, required a design that would showcase the Centre's capabilities while also delivering performance improvements for the skiers. The challenge was to understand the performance of existing Sit-skis, build kinematic models of the suspension behavior, and design a system that would be lighter and more efficient. The design process needed to consider the use of composite structures at an architecture/system level, and the importance of cost and manufacturability in the product development process. Read More
About Customer	The National Composites Centre (NCC) is an open-access, industrial-scale, state-of-the art non-profit UK facility for technology development in the manufacture of advanced composites. Established by the University of Bristol, the NCC aims to accelerate the growth of UK industrial output by enabling design and manufacturing enterprises to deliver winning solutions in the application of composites. Since its inception in August 2011, the facility has doubled in size and serves as the primary composites catapult facility in the UK, playing an integral part in the UK’s composites initiative since the government launched its Composites Strategy in November 2009. Read More
Solution	The NCC, in collaboration with the Manufacturing Technology Centre (MTC), Advanced Manufacturing Research Centre (AMRC) and University of Warwick (WMG), used simulation-driven design for the assessment of performance and structural reliability before manufacturing any component. The Altair HyperWorks™ suite was utilized throughout the development process. Altair MotionSolve™ was used to model the kinematic behavior of an existing coil-over suspension system and compared to the new composite leaf spring and damper concept. Altair HyperStudy™ was used in conjunction with Altair MotionSolve to optimize the kinematic behavior and assess the positions and sizes of various structural and suspension elements. Altair OptiStruct™ was used to perform detailed sizing of the laminates in the spring and chassis elements along with the use of the morphing capabilities in Altair HyperMesh™ to optimize the geometry. Altair Inspire™ and Altair Evolve™ were used for visualizing the full assembly and producing images for the reports and presentations. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Equipment & Machinery

Plastics

Applicable Functions

Facility Management

Product Research & Development

Use Cases

Manufacturing Process Simulation

Virtual Reality

Services

System Integration

Challenge

The National Composites Centre (NCC), a non-profit UK facility, was tasked with the development of an advanced technology demonstrator, a Sit-ski, using composite materials. The Sit-ski, a device used for sports on mountain slopes by individuals with lower extremity limitations, required a design that would showcase the Centre's capabilities while also delivering performance improvements for the skiers. The challenge was to understand the performance of existing Sit-skis, build kinematic models of the suspension behavior, and design a system that would be lighter and more efficient. The design process needed to consider the use of composite structures at an architecture/system level, and the importance of cost and manufacturability in the product development process.

About Customer

The National Composites Centre (NCC) is an open-access, industrial-scale, state-of-the art non-profit UK facility for technology development in the manufacture of advanced composites. Established by the University of Bristol, the NCC aims to accelerate the growth of UK industrial output by enabling design and manufacturing enterprises to deliver winning solutions in the application of composites. Since its inception in August 2011, the facility has doubled in size and serves as the primary composites catapult facility in the UK, playing an integral part in the UK’s composites initiative since the government launched its Composites Strategy in November 2009.

Solution

The NCC, in collaboration with the Manufacturing Technology Centre (MTC), Advanced Manufacturing Research Centre (AMRC) and University of Warwick (WMG), used simulation-driven design for the assessment of performance and structural reliability before manufacturing any component. The Altair HyperWorks™ suite was utilized throughout the development process. Altair MotionSolve™ was used to model the kinematic behavior of an existing coil-over suspension system and compared to the new composite leaf spring and damper concept. Altair HyperStudy™ was used in conjunction with Altair MotionSolve to optimize the kinematic behavior and assess the positions and sizes of various structural and suspension elements. Altair OptiStruct™ was used to perform detailed sizing of the laminates in the spring and chassis elements along with the use of the morphing capabilities in Altair HyperMesh™ to optimize the geometry. Altair Inspire™ and Altair Evolve™ were used for visualizing the full assembly and producing images for the reports and presentations.

Impact #1	The use of a combination of Altair software products allowed for an entirely virtual assessment of performance and structural reliability before any component was manufactured. This approach significantly reduced the development time to less than 3 months. The resultant initial design of the Sit-ski was about 15% lighter than other similar devices available on the market. Physical testing carried out at the component and assembly level validated the models, demonstrating good correlation with the predicted response of the spring component and overall kinematic behavior of the assembly. The skiers felt that the device was different and were excited by its potential, expressing interest in seeing it developed further.

Impact #1

The use of a combination of Altair software products allowed for an entirely virtual assessment of performance and structural reliability before any component was manufactured. This approach significantly reduced the development time to less than 3 months. The resultant initial design of the Sit-ski was about 15% lighter than other similar devices available on the market. Physical testing carried out at the component and assembly level validated the models, demonstrating good correlation with the predicted response of the spring component and overall kinematic behavior of the assembly. The skiers felt that the device was different and were excited by its potential, expressing interest in seeing it developed further.

Benefit #1	Reduced development time to less than 3 months
Benefit #2	Design of a 15% lighter, innovative product

Benefit #1

Reduced development time to less than 3 months

Benefit #2

Design of a 15% lighter, innovative product

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Overview

Innovative Sit-Ski Development through Composite Technology at National Composites Centre

Operational Impact

Quantitative Benefit