Ford Motor Company adopted Altair Inspire and HyperStudy to improve additive manufacturing design for automotive components. As AM expertise varied across teams, Ford needed a way to predict failures and optimize print parameters before production. Using 3D printing simulation and design-of-experiments workflows, engineers evaluated support detachment, deformation, thermal behavior, and surface finish. Internal cooling channels were optimized for heat dissipation while maintaining dimensional accuracy. Simulation results correlated well with physical testing, enabling first-time-right designs. The approach reduced production risk, improved component quality, and helped Ford integrate additive manufacturing more confidently into vehicle development.

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