BMW integrated machine learning into its crashworthiness optimization workflow to reduce development time and manage complex, competing design constraints. Using Altair ML tools within HyperWorks, engineers applied clustering and classification algorithms to identify favorable crash kinematics and embed expert knowledge into optimization constraints. This AI-enhanced surrogate modeling reduced the number of required simulations and simplified optimization problem formulation. The approach improved insight into energy absorption, deformation behavior, and weight trade-offs. BMW now uses AI to augment human expertise, streamline crash design, and explore future applications across vehicle development.

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