Automotive Suspension Swing Arm Multi-Process Generative Study
.avif)
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.
Results
- 28% mass reduction versus the legacy forged steel swing arm
- Full manufacturability compliance for both CNC machining and die casting
- Engineering lead time reduced from 6 weeks to 4 days
- Single parametric workflow serving both product line variants
Interested in reading the full case study?
Fill in the form below to instantly receive the full case study.
Aeronautics Challenges We Address
FAQs
Explore our frequently asked questions to understand how our software can benefit you.
Cognitive Design's manufacturing-driven design approach embeds process-specific constraints, including tool access directions for CNC and draft angle rules for die casting, from the first optimization iteration. A single generative session produces two production-ready geometries simultaneously, without running separate engineering programs or rebuilding the optimization logic for each manufacturing route.
In a documented suspension swing arm case, the CNC-optimized Al-6061-T6 variant was validated at $145 per part with zero tooling investment, suited to a limited sports edition. The die-cast variant achieved $32 per part after tooling amortization across 100,000 units. Both geometries were derived from the same generative study, with no additional engineering effort required to produce the second route.
Cognitive Design compressed parallel design, simulation, and supplier coordination for a suspension swing arm from 140-180 hours to 12-20 hours, a 90% reduction in engineering lead time. This allowed the client to launch a limited sports edition immediately while preparing die-casting tooling for volume production in parallel.
The CNC-optimized Al-6061-T6 swing arm dropped from 3.20 kg to 1.92 kg, a 40% mass reduction. Despite the significant material removal, deflection performance was maintained at 0.48 mm compared to the 0.45 mm baseline, and a safety factor of 1.5 was preserved across all multi-axial load cases including bump, cornering, and braking.
Yes. Cognitive Design's integrated FEA environment handles simultaneous multi-axial loading conditions, including vertical bump loads, lateral cornering forces, and longitudinal braking inputs. Manufacturability constraints for each target process are evaluated in the same workflow, eliminating the need for sequential design-simulate-review cycles typical of conventional suspension development programs.
Automotive Challenges We Address
Defense Challenges We Address
Built for the Cognitive Era of Engineering
Shorten product development cycle from the earliest concept phase.
Product engineering cycle
Product engineering cycle
Reusability of engineering workflows
Unlock Your Design Potential
Request a demo to see how Cognitive Design by CDS can revolutionize your engineering workflow