FlexCrash partner Aerobase Innovations presented the project’s approach to predicting the crash performance of high-pressure die-cast aluminium components during the WIRA-ICME Collaboration Days, held on 21–22 October 2026 at KTH Royal Institute of Technology in Stockholm.
The event, organised by the Innovative Materials Arena (IMA), brought together industry and academia to discuss advances and future priorities in Integrated Computational Materials Engineering (ICME). Within this framework, Aerobase Innovations held a dedicated meeting with Volvo Cars, where Bijish Babu presented the FlexCrash casting-to-crash workflow and its potential to improve the prediction of component behaviour under crash conditions.
A key feature of the workflow is its ability to account for material variability throughout the simulation process. Tensile tests on specimens taken from the same casting can show failure strains ranging from 11% to 17%. FlexCrash addresses this variability by transferring information from the casting simulation to the crash mesh, where Aerobase’s SafeLight model assigns each point on the component a probability of failure.
