Automotive Suspension Swing Arm Multi-Process Generative Study

In automotive and EV platforms, every gram of unsprung mass translates directly into range, handling, and ride quality. An over-designed suspension swing arm was limiting vehicle dynamics across two product lines. An automotive manufacturer partnered with Cognitive Design to deliver a single optimized topology serving both a limited-run sports edition and a mass-market model.

The core challenge: suspension components endure punishing multi-axial loads (bump, cornering, braking) simultaneously, and designing for two manufacturing processes (CNC machining for low volumes, die casting for scale) traditionally means running two parallel engineering programs with separate CAD models, FEA campaigns, and supplier reviews.

With Cognitive Design, the team generated both a machining-ready and a casting-ready geometry from a single topology optimization, with manufacturability constraints embedded from the first iteration.

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Results Achieved

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90% faster engineering

‍The integrated workflow compressed what would traditionally require 140-180 hours of parallel design, simulation, and supplier coordination into 12-20 hours, enabling the client to launch the sports variant immediately while tooling up for mass production.

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Two manufacturing routes from one study

‍A single generative session produced two production-ready geometries: a CNC variant at $145 per part with zero tooling investment for the sports edition, and a die cast variant at $32 per part after amortizing tooling across 100,000 units for volume production.

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10% mass reduction

‍The CNC-optimized Al-6061-T6 swing arm dropped from 3.20 kg to 1.92 kg while maintaining deflection parity (0.48 mm versus 0.45 mm original) and a consistent factor of safety of 1.5 across all load cases.