Etteplan Oyj partnered with Altair to redesign a heavy cast-steel extension boom-end used in tree harvesters, targeting improved performance and manufacturability across additive manufacturing and casting. Using Altair Inspire, OptiStruct, Inspire Cast, and simulation-driven design workflows, Etteplan applied topology optimization, implicit modeling, and lattice-supported organic geometries. The design was validated using FEM and fatigue analysis, then adapted for casting through modified constraints, scripting, and solidification checks. The additive version achieved a 66% weight reduction with exceptional fatigue performance, while the cast version delivered a 53% reduction. The project demonstrated how simulation-led optimization enables adaptable, production-ready designs across multip

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