X-Plast partnered with Knorr-Bremse to replace metal railway components with high-performance plastic alternatives. Using Altair simulation tools, the team applied topology optimization, nonlinear analysis, and injection molding simulation to ensure durability, stiffness, and long-term reliability. The integrated workflow accounted for anisotropic material behavior and real-world operating conditions. The resulting plastic component achieved a 25% weight reduction, 35% cost savings, and a guaranteed 30-year lifetime. Simulation enabled faster development, reduced prototyping, and demonstrated that sustainable materials can outperform traditional metal solutions.

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