Automotive Upright Lightweighting and Multi-Process Cost Analysis

In the race to reduce unsprung mass and maximize EV range, every gram counts. But traditional CAD workflows force engineers into an impossible choice: spend weeks iterating on topology optimization across multiple manufacturing processes, or settle for the first feasible design and leave performance on the table.

This case study documents how a high performance automotive team used Cognitive Design to break that compromise. Starting with a legacy steel upright that was clearly over engineered but difficult to improve with conventional tools, we generated and evaluated 100+ design variations across three distinct manufacturing pathways (additive manufacturing, CNC machining, and die casting) in a single integrated workflow.

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Results Achieved

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30% mass reduction

‍The optimized Ti 6Al 4V upright achieved a 30% reduction in mass compared to the legacy steel design, dropping from 3.20 kg to 2.24 kg while maintaining structural integrity under critical braking and cornering loads.

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96% faster engineering

‍Using Cognitive Design's integrated workflow, the engineering team compressed design exploration and validation from 96 hours with conventional software to just 4 hours, enabling rapid evaluation of over 100 manufacturing ready variations.

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8 weeks to 5 days

‍By eliminating traditional tooling requirements through additive manufacturing, the team reduced production lead time from 8 weeks for cast parts to 5 days for printed components, accelerating time to prototype and testing.

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