Accurate and performant finite element analysis of giga-cast parts

Aluminum gigacasting is rapidly reshaping the automotive industry, unlocking a powerful path toward unprecedented profitability. Traditional vehicle assemblies often consist of parts made using a variety of techniques—such as die-casting and sheet-metal forming—that are then painstakingly joined through methods like welding and fastening. This results in higher costs and greater complexity in production. Gigacasting involves the use of large-scale die-cast aluminum components to replace traditional multipart assemblies, revolutionizing the manufacturing process. The potential for cost savings is immense, driven by superior precision and tolerances. However, automakers rely heavily on engineering simulation for performance and safety testing, and it is not well-suited to the specific requirements of large-scale aluminum gigacast parts. Simulating giga-cast parts using existing tools is extremely time-consuming and expensive. This project offers a compelling solution by enabling direct simulation of aluminum die-cast parts on highfidelity design models, bypassing many of the workflow steps that make traditional automotive simulation so costly. The enabling technology is an innovative approach that is based on higher-order smooth spline elements. In Phase I of this project, enough progress was made on this new automotive workflow that an entire simulation of a gigacast assembly was set up and executed in just a few hours, instead of weeks. This demonstrated the transformative impact of the software on automotive simulation processes. This Phase II project aims to enhance the performance and scalability for simulating complex gigacast assemblies. The project will include close coordination with automotive manufacturers to ensure good product/market fit. The technology to be developed in this project offers the opportunity to dramatically reduce simulation time, enhance accuracy, and eliminate redundancies in the simulation of automotive gigacast parts. By consolidating both thin and solid part simulations into a single, streamlined process, manufacturers can accelerate product development, reduce costs, improve user safety, and minimize the risk of errors. This technology may facilitate the future of automotive design and production.