Automotive

Accelerating the Design of a Castable Gearbox Housing for a Hybrid Vehicle

In the race toward electrification, automotive OEMs face mounting pressure to reduce development timelines while managing increasing architectural complexity.
Accelerating the Design of a Castable Gearbox Housing for a Hybrid Vehicle

Gearbox housings remain as one of the car components that must now respond to continuous system evolution: changes in electric motor packaging, inverter positioning, new cooling layouts, shifting loadpaths... Design engineers are on the front line, responsible for delivering parts that fit evolving assemblies, meet performance targets, and comply with casting-specific manufacturing rules. However, fragmented workflows and rigid CAD processes make this task time-consuming and error-prone.

This case study focuses on the design of a castable gearbox housing for a next-generation hybrid vehicle, showing how the integration of performance and manufacturability constraints within an automated workflow allows engineers to deliver more reliable, and production-ready results 10 times faster, even when system definitions change mid-stream.

The optimized part

Gearbox housing 2s_edited.png

The outcomes

Engineering lead time reduction:
10 times faster (from 5 days to 12 hours) than conventional casting design workflow.​

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FAQs

Explore our frequently asked questions to understand how our software can benefit you.

Does the platform use AI? Is it trained on my own data?

Yes, some functions in Cognitive Design by CDS use AI (costing, conversion to CAD, manufacturing analysis). It is pre-trained by CDS and packaged in the software, so there is no training happening on your side, and your data is not used.

Can I export my geometries to CAD?

Yes, you can convert mesh or implicit models to CAD and export them as a .step. It works best for midly complex models (e.g. generative design results). Complexe models (integrating lattice structures for instance) can also be converted to CAD, but would take more time..

Do I loose sharp features on my models when converting them to implicit?

No, our workflows use hybrid meshing, keeping the original CAD precision around functional regions, and having smooth mesh elements on organic features.

What modeling technology is used inside Cognitive Design by CDS?

Cognitive Design by CDS uses a proprietary hybrid geometrical engine, mainly based on implicit modeling (Signed Distance functions), with in addition mesh and CAD operators.

What licensing options are available for Cognitive Design by CDS?

Cognitive Design by CDS uses a node-locked license system, tied to each workstation. This approach aligns with the offline, on-premise setup. Floating licenses are not yet available.

What types of parts can be designed with Cognitive Design by CDS?

Cognitive Design by CDS is particularly well suited for complex, high-value mechanical parts such as lightweight structures, gearbox housings, functional brackets, or fixtures subjected to multiphysics loads. It is optimized for use cases in aerospace, defense, space, and advanced mobility systems.

What is Cognitive Design by CDS?

Cognitive Design by CDS is an advanced concurrent plaftorm for design optimization that enhances component performance. It incorporates production constraints directly into the design phase, ensuring efficiency. This allows design engineers to streamline workflows and reduce development time.

Who can use it?

Cognitive Design by CDS is tailored for engineers in large and medium-sized industrial companies. It is particularly beneficial for sectors like aerospace, automotive, defense, and space. The software addresses unique engineering challenges faced in these industries.

How does it work?

Cognitive Design by CDS uses an implicit modeling engine and parametric design to generate and optimize designs rapidly. By factoring in manufacturing constraints, it ensures that designs are feasible and efficient. This process minimizes the risk of failure during production.

What are the benefits?

Cognitive Design by CDS significantly reduces development time and enhances agility in the design process. It allows for quick iterations and optimizations, keeping your projects on track. By integrating manufacturing constraints early, it helps maintain competitiveness.

Is training required?

While Cognitive Design by CDS is user-friendly, we offer comprehensive training to maximize its potential. Our support team is available to assist with onboarding and any questions. This ensures that users can leverage the software effectively.

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