Hero MotoCorp adopted Altair PhysicsAI to accelerate motorcycle component development by replacing time-intensive FEA with AI-powered simulation. The initial focus was a motorcycle handlebar, a critical component affecting ergonomics and performance. PhysicsAI models were trained on historical simulation data and integrated directly into Altair HyperWorks workflows. Once trained, the AI predicted stress results within minutes instead of hours, achieving less than 3% variation compared to traditional FEA. Development time was reduced from one hour to three minutes per design iteration. The solution enabled faster decision-making, broader design exploration, and upskilled engineering teams, paving the way for expanded AI-driven product development at Hero.

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