Supported by Innovate UK and the Advanced Propulsion Centre (APC), the project aims to transform vehicle manufacturing by creating lighter, more sustainable components using Altair’s artificial intelligence (AI) and simulation capabilities.
Led by Sarginsons Industries, the PIVOT project brings together key partners including Aston Martin, Brunel University London, and metal recycling specialists GESCRAP.
The initiative will develop software that combines casting simulation, topology optimisation, and AI, which will enable organisations to design components optimised for weight, structural performance, and manufacturability.
According to Altair, these breakthroughs will result in cast aluminium structures that are up to 30 per cent lighter while maintaining performance requirements.
“This collaboration demonstrates how our AI-powered engineering technology enables manufacturers to develop more efficient vehicle components, cutting down on weight and drastically reducing environmental impact,” Sam Mahalingam, CTO at Altair said in a statement.
Funded in part by a £2.9m government grant from Innovate UK and APC, the PIVOT project will focus on using 100 per cent recycled aluminium to reduce embedded carbon emissions in vehicle components by up to 95 per cent.
By overcoming mechanical weaknesses inherent in recycled aluminium through advanced grain refinement techniques developed by Brunel University, PIVOT will make it possible to use secondary alloys for cast structural applications such as vehicle chassis systems.
“PIVOT represents a huge step forward for the casting industry,” said Mark Nunan, managing director, Sarginsons Industries. “With Altair’s…technology, we are pushing the boundaries of what’s possible, creating components that are not only lighter and stronger but also significantly greener.”
The PIVOT project will serve as a showcase for how AI, recycled materials, and advanced casting processes can reshape vehicle manufacturing while reducing environmental footprint. The project is expected to deliver critical advancements in the coming years, enabling OEMs and foundries to adopt more efficient and sustainable production methods.
PIVOT is one of eight projects sharing £29.6m of UK government funding from the APC facilitated Collaborative Research and Development funding round.
According to APC, the technologies under development aim to boost economic growth and are projected to create or safeguard over 3,500 jobs and reduce CO2 in the manufacturing and use of zero-emission vehicles.
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