Research Report: Simulation-Driven Design for Manufacturing (SDfM) Experiences

Product engineers are under consistent pressure to reduce the costs, improve the quality and increase the throughput of manufacturing processes. This fast-paced environment is not well suited for trial-and-error manufacturing engineering. How are engineers responding to these challenges? Is simulation and simulation-driven design for manufacturing (SDfM) well established across the industry? When simulation is deployed, does it deliver on the promises of reducing costs while improving throughput and quality? And what are the barriers to the adoption of simulation during the early stages of product development? In this 2021 survey report conducted by, we discuss those questions and discover: • Top design priorities • Top benefits of SDfM • Top barriers to expanding and adopting SDfM • Risks to staying competitive in the market

Technical Document

Workshop: The Role of Simulation From Concept Development to Final Design

This workshop demonstrates how a simulation-driven design approach to product development can have a drastic impact on the performance, design time, and profitability of a new product. Using a belt sander tool as a demonstration model, our presenters show how Altair’s design and simulation technologies can conduct a concept design analysis and optimization of the sander external housing to improve stiffness and reduce weight. They go on to show how we can simulate the manufacturing process itself by looking at filling, packing, cooling and warpage of the plastic housing; before concluding with a series of stress analysis and validation studies such as a virtual drop test, 3-point bending simulation and even a study of the effect of the heat transfer of the electric motor. This is a valuable session to see how simulation technologies can be used throughout the design process, adding value and reducing development time at each stage. Speakers: Ujwal Patnaik, Global Business Development Manager, Altair Chris Sambell, Application Engineer, Altair Duration: 60 minutes

Conference Presentations

Molding and Structural Simulation of Injection Molded Parts

This workshop on molding and structural simulation of injection molded parts was conducted by Frank Ehrhart, EMEA Technical Specialist - Material Engineering/Multiscale Designer. The recording is a little over an hour long, and and was first presented at the 2020 ATCx Composites.

ATCx Composites 2020

Guide to Consumer Electronics Design and Packaging

To get a beautifully designed electronic product safely delivered to your customer, the work must start at the product design phase. Leveraging simulation-driven design, manufacturers are gaining greater insight and control over the development of innovative products, consistent manufacturing processes, and cost-effective, sustainable packaging.


Altair Inspire Mold Overview

Inspire Mold is a complete molding simulation in 5 easy steps through a highly intuitive user experience, catering to beginners and experts alike allowing designers and product engineers to improve part performance while reducing defects and iterations between design and manufacturing. Visit to learn more and begin your free trial today.


Inspire Mold 2020 Introduction

In this course, you will have the opportunity to learn about the Inspire Mold 2020 interface along with tools and workflows contained within Inspire Mold. Modules contained within the course provide detailed descriptions of the tools and workflows within Inspire Mold. You will also have the opportunity to watch and perform hands-on exercises within each module.


Breaking the Mold: Altair Inspire Mold Product Launch

With automatic mold generation, instantaneous configuration testing, and always-3D adaptive computation, our design simulation technology is mind-bogglingly fast, friendly, and accurate. Get a better understanding of part filling, packing, cooling, warpage, while reducing molding defects long before a mold is designed. The results? Reduce concept and testing times from days to hours, and hours to minutes. Cut product development costs Make better product design decisions early Deliver production-ready tools on time and on budget Questions? Go to the Inspire Mold Community and participate to the discussion!


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.


Virtual Product Design of a Medical Autoinjector

Sweden-based Nolato, a global provider of injection molded parts for numerous industrial and medical applications has developed Nolava as a collaborative project with companies including Altair and Avalon Innovation. Nolava is Nolato’s medical self-injector, a complex electro-mechanical device housed in an injection molded fiber-reinforced plastic body. Applying Altair’s state-of-the-art integrated simulation-driven design solution showed that virtual prototyping early in the design stage of development saves time and money by resolving problems before making a physical prototype or the associated manufacturing tooling.

Customer Stories

Introducing Altair Inspire Mold

Altair Inspire Mold provides a modern integrated approach to streamline design for manufacturing (DfM) of injection molded components.