Optimal Device: Using Tosca to Design for Different Manufacturing Processes

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Rob Stupplebeen’s company name, Optimal Device, reflects his enthusiasm for the power of optimization. A longtime Abaqus user whose consulting and training team focuses on medical devices, he has employed SIMULIA’s Isight, Tosca and Simpoe-Mold to help design everything from ballistic face shields for the military to precision optics for space telescopes. He also likes to showcase the occasional “goofy” design just for fun.

“Tosca is as close to magic as you can get with simulation” – Rob Stupplebeen, Optimal Device

A former high-school lacrosse player, and now a coach for his eight-year-old son, Rob recently began a use-case blog about lacrosse-stick head design, which he turned into a paper for the 2016 Science in the Age of Experience event in Boston. Stupplebeen began by comparing the equipment he played with in the past to the sticks in use today. “When looking at my old lacrosse head, I saw noticeable differences between it and the more modern ones,” he says. “It had clearly evolved from my time, as an injection-molded industrial-design with manufacturing constraints, to the current engineering-driven design with a truss structure of varying angles and sizes. This kind of organic truss structure is essentially what topology optimization evolves towards.”

Starting from the NCAA rules regarding stick dimensions, Stupplebeen created a CATIA model of the head component with the largest permissible amount of material. Then he brought the drawing into Abaqus. “Once you have that working FEA model it can include nonlinearities because of Tosca’s unique abilities to handle nonlinear topology optimization,” he says.

Work went quickly, Stupplebeen reports. “From opening up the rule book to having a viable design on-screen only took a couple days and I produced something remarkably similar to recent commercially available injection-molded designs,” he says. “I also was able to do it all on my own. Topology optimization provides a huge amount of power and intuition into a design without a lot of labor at your end.”

Want to learn more?

Discover how Optimal Device leverages simulation to optimize the design of the lacrosse stick head!

Read the Topology Optimization of a Lacrosse Head Solution Brief

Creativity Unleashed at the AEC Design Hackathon

By Akio
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At Design in the Age of Experience 2017 AEC Hackathon, we brought 13 CATIA R&D experts from Dassault Systèmes together with 17 architectural design professionals from the world’s most progressive firms, including:

  • hackathon Milano 4-5 April 2017Zaha Hadid Architects
  • SHoP Architects
  • HKS Architects
  • Kengo Kuma and Associates
  • Morphosis
  • CO Architects
  • New Jersey Institute of Technology
  • CadMakers

The objective of the hackathon was to create innovative building designs in under 24 hours with CATIA’s latest generative modeling applications on the 3DEXPERIENCE platform.

hackathon 00

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Champion users from the 3DEXPERIENCE Construction TRIBE formed 6 teams and spent 24 hours straight creating more than 60 lifelike renderings.

With the help of 83 pizzas, 312 espressos, and 3 coordinators, the hackathon participants explored multiple design options before each team converged on a final project. This was all executed on the cloud using the latest AEC solutions for the 3DEXPERIENCE platform.


The hackathon culminated with a presentation and a virtual reality experience in the Design in the Age of Experience playground.

hackathon stage

clicktotweetTweet: Creativity Unleashed at the @Dassault3DS #AEC
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Get a taste of the action through these video highlights:

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Related Resources

AEC Industry Solution Experiences from Dassault Systèmes

Groupama Team France: Striving for Excellence in the 2017 America’s Cup

By Alyssa
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From May 26th to June 27th, the 35th edition of the oldest and most prestigious sailing competition – the America’s Cup – will be disputed off the coasts of Bermuda.

A race like this is truly a contest of know-how and technology.  Achieving excellence within a very short timeframe is key to success; race rules dictate that boats couldn’t be water tested until December 26, 2016 – a mere five months prior to the first official race.

One of the six teams entering in this edition is Groupama Team France.  Since Groupama Team France formed later than their competitors, they had to build and test their flying catamaran within 18 months, whereas their rivals had a time frame of up to three years.  The team of 85 includes passionate designers, engineers, mathematicians, physicists, communications specialists and sailors who recognized that optimal preparation required two critical components: a way to not only design but also test many different ideas to develop their boat and the use of a single collaborative platform to streamline communication between both internal teams and external partners working on different parts of the development process.  Groupama Team France adopted the Designed for Sea industry solution experience based on the 3DEXPERIENCE® platform from Dassault Systèmes to address both goals.

Designed for Sea allowed the team to model everything in 3D, design the foil, analyze the structure, and simulate the boat’s behavior in the water. The resulting 3D virtual mockup provided the crew with a precise idea of the boat before construction even began. It also enabled the design team to build a strong boat yet lightweight and safe when “flying” over the water at 80 km per hour. Thanks to the 3DEXPERIENCE platform all applications are now integrated into one environment, where in the past multiple tools were needed for 3D modeling, structural analysis, collaboration, flow simulations and optimization.  This saved precious time and prevented errors.

As Martin Fischer, head of the design team at Groupama Team France summarized: “[The 3DEXPERIENCE platform] allows us to easily exchange 3D models and construction plans with [external partners] and, if there are issues to resolve, our communication is more efficient, new ideas flow and errors that might otherwise go unnoticed are more easily corrected. It all boils down to time. If communication is streamlined, the design process is quicker leaving more time to run tests and optimize our boat.” 

Check out the full story and learn more about how Groupama Team France is leveraging Dassault Systèmes’ solutions to unleash the required innovation to perform in the sailing world’s most renowned and difficult competition.

You can also get a look at the boat in a new video.


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