We develop economical lightweight components by using mathematical optimization
Applicable to any industry and any manufacturing process
Revolutionary component development - comprehensively implemented
For which of your components would redevelopment be the most profitable e.g. in terms of lightweight design? Which components could be manufactured more economically using 3D printing? We clarify the question of economic efficiency and identify which of your company’s components we believe provide you with the most benefits. The identification is free of charge and provides you with a non-binding overview of the hidden potential within your assemblies. You can arrange a free consultation by going to our contact request page. If you already have part in mind, you can also use our free automated identification tool: amvaluation
The variety of manufacturing processes and available materials has become enormous. 3D printing manufacturing processes bring further possibilities. During specification, we record your requirements and use these constraints to select the ideal manufacturing method and material. While the focus is on 3D printing, conventional manufacturing processes are also taken into account when determining the ideal approach to manufacturing for your application.
Through our simulation driven component development process (see development process), we are able to tailor your part designs perfectly to your applications. We can prioritize several different objectives such as lightweight construction, minimum manufacturing costs or the increase/reduction of thermal conductivity. It is possible to select from several different mechanical or thermal properties to be the desired optimization target. The resulting designs provide the maximum performance with the minimum material used at the lowest possible manufacturing cost. At the same time, we guarantee the operational safety and manufacturability of the components we design. Not able to imagine the difference yet? Click here for some sample projects with before-and-after comparisons from the automotive– and machinery industry.
If you have already performed your own topology optimization, we also offer geometry greturn of the results into CAD solid models separately. In doing so, we guarantee a minimal deviation between the result of the topology optimization and the final component geometry. Uneven, discontinuous, “not watertight” and generally error-prone STL files are no problem and can be exported in STEP or IGES file format after the return process. The files are subsequently fully editable in any common CAD program.
By combining simulation and physical testing, we reliably ensure the manufacturability and fatigue strength of your component. We have a database of a wide range of material models that are used to reliably calculate the fatigue life of these components. The use of process simulation of the various manufacturing methods, 3D printing or conventional, enables the avoidance of potential manufacturing issues down the line.
Through our large network of manufacturing partners, we can find and commission the ideal production partner for your component. We coordinate the manufacturing and ensure that delivery times are met. All of the required manufacturing parameters are defined by us in consultation with you, so there is no need for specific manufacturing know-how on your part. We have carefully selected our manufacturing partners in order to guarantee the highest quality. In addition, we have extensively tested manufactured components from our partners through both non-destructive and destructive testing to eliminate any uncertainties. Materials used during manufacturing are also qualified by our own in-house testing in order to verify potentially inaccurate manufacturer material specifications.
By saving material or changing the previously used manufacturing process, production costs are drastically reduced. You don’t have to purchase costly software or machinery, and you don’t have to train employees to use such tools. In addition, we can offer the best prices for manufacturing through our network of manufacturing partners. Getting started is straightforward with our free part identification service.
Lightweight design plays a very important role, especially for moving components. Reduced weight inherently reduces dynamic forces and provides you with benefits from secondary effects such as: increased travel speed for your production equipment, reduced energy consumption, increased tool life or simplified component handling.
Optimized thermal behavior
The aim of component optimization can also be to improve the part’s thermal properties, so that cooling and heating problems are eliminated by the optimized component structure. Depending on the application, you benefit for example through less wear, increased performance in thermally-stressed components and reducing required additional cooling and heat sources.
Shortest development time
Reduce your time-to-market. By eliminating manual design steps in our development process, we can develop parts up 80% faster while being able to respond flexibly to your desired changes.
Development example - machinery
Lightweight Pick & Place Machine
By optimizing four components of the pick & place machine, the moving mass was reduced by 29.8 kg. The components were optimized for three different manufacturing processes in order to generate an ideal relationship between cost and performance. Eleven components were combined into four parts. This improves the assembly effort and handling. Two linear guides and 25 screws were saved. Fatigue strength and manufacturability are fully assured. Due to the reduced moving mass, 52% less energy is required to perform the movements. The result is either 34% faster production or 52% reduced energy costs. 1270€ of energy costs are saved per year per machine.
We investigate the potential of optimized components for your machines free of charge.
Before / after comparison & technical data of the optimized components
Bitte führe ein Update deines Browsers durch oder verwende einen der folgenden Browser:
Google Chrome Version 23 oder höher
Firefox Version 65 oder höher
Opera Version 19 oder höher
Microsoft Edge Version 18 oder höher
iOS Safari Version 14.3 oder höher
Connection Y - Z axis
Base plate Z-axis
Console pneumatic unit
We would be happy to discuss possible applications of optimized components on your machines/plants/.. and look at other potential components.
Development example - Automotive
In the development of this cast aluminum component, amprove was able to reduce the weight by 600g. This reduces the material costs per piece by about 1,50. The cost of mold construction is taken into account during development. The reduced weight of the brake caliper reduces CO2 emissions and increases the range of electrified vehicles, for example. Lightweight design of high-volume components therefore provides a major contribution towards meeting the required fleet emission targets.
For small batch applications, the part can be optimized for tool-less 3D printing. The design freedom of 3D printing enables further material savings and the creation of high-performance components. The cost of 3D printing depends largely on the machine time. Our developments drastically reduce the mass of the component and thus the machine time required for production.
We would be happy to discuss possible applications on your vehicles and look at other potential components.
How we develop components
Simulation replaces CAD-construction
Load & design space definition
Based on existing information such as CAD data, values for applied forces and pressures, information on masses and directions of motion, or photos and videos of your application, the maximum available installation space is designed and the finite element model with all load cases is built. Ideally, simulation models and design spaces already exist. In general, the more data provided, the closer the result is to the optimum.
Topology & shape Optimization
Topology and shape optimizations are performed within the developed design space. For the given load cases, the geometry is optimized under suitable restrictions with regard to the optimization objective, e.g. minimizing the mass. During this process, all constraints are defined keeping in mind the desired production process to ensure manufacturability. Both conventional manufacturing processes such as casting and milling as well as additive manufacturing processes (3D printing) can be taken into account. No further information is required on your part.
In order to preserve the optimized result of the topology and shape optimizations, further steps are taken directly on the output of the solver. The generated density distribution is fed into a parameterizable geometry, which can then be further used in all commercial CAD programs. The new geometry is a fully functional solid model, which can be exported as a STEP file, for example. The deviation between the result of the topology optimization and the final component’s geometry is very small due to the elimination of the manual post-design work.
The result of the optimizations is then finally validated. Various simulations are considered. On one side, fatigue analyses are carried out to ensure the safe operation of the component, and on the other side, process simulations are performed to enable cost-effective and trouble-free production. Depending on the application, additional properties such as NVH behavior or thermal resistance can be taken into account. At the same time, these properties can also be prescribed as part of the optimization.
The result is an optimal, fatigue-proof component that can be manufactured reliably and cost-effectively in the selected manufacturing process. Every component structure has a function. Maximum performance at minimum cost.
Our team consists of engineers with more than twelve years of experience in simulation-driven component development. Most of our experience comes from the automotive and motorsport sector. There we dealt with many CAE and CAD topics centered around structural optimization. In addition to conventional manufacturing processes such as casting and milling, we have increasingly focused on various additive manufacturing processes (3D printing).
improve by amprove.
With simulation driven component development, practically any component can be driven to its maximum efficiency and performance. Contrary to popular assumptions, manufacturing costs are often reduced rather than increased during this process. Our desire is to update the hardware world with our development work and to do our part to reduce unnecessary material waste. As a company, we aspire to act as a part supplier in the future by building up a portfolio of self-developed, efficient hardware.