Altair HyperXtrude 2026 Release Notes

Altair HyperXtrude is a suite of finite element solvers for simulating the following manufacturing processes, and these solutions have interfaces in Inspire. The HyperXtrude solver is also known by the name Inspire Extrude Solver.
  • Binder Jet Sintering
  • Metal Extrusion
  • Polymer Extrusion
  • Quenching
  • Calibration
  • Metal Rolling
  • Friction Stir Welding
  • Resin Transfer Molding

General

New Features

Pardiso linear equation solver
As part of ongoing solver development aimed at enhancing parallel performance, the Pardiso linear equation solver is implemented as an initial step. This integration also establishes the foundation for incorporating additional linear solvers in the future. In this release, Pardiso is not configured as the default solver and is not accessible through the Inspire Extrude interface. However, it can be invoked manually via the input data file. This will be formally made available in the next release.

Metal Extrusion

New Features

Smoother flow front in die filling analysis
Filling front predicted by the die filling analysis is made smoother by removing the digital filtering and implementing a distance function. (GIT-ec78e8e3)

Enhancements

Weld surface determination
Weld regions are identified by tracking material flow from each porthole. When the number of portholes exceeded 15, this process required significant computational time. The algorithm has now been optimized, resulting in improved performance. For this analysis type, the solver supports up to 30 portholes. (SLVHXT-831)

Resolved Issues

  • There are no longer instances where the solver fails to terminate the run in case of errors found in the input boundary conditions data. (SLVHXT-815)
  • The change to compute gap thickness introduced in version 2025.1 is now applied only when the pset parameter MeshPerturbationDCT is set to 1. The default value of this parameter remains 0. This reverts the code behavior to its previous state in version 2024.1 and resolves issues observed in a few models. (SLVHXT-829)
  • Fixed an issue where bearing friction was affected in profiles that were uniformly thick but contained minor thickness variations due to CAD irregularities. The problem arose from how the non-dimensional gap thickness was computed and applied, leading to oscillations in stick-slip zones. (SLVHXT-798)
  • Fixed an issue that caused certain informational printouts to be repeated for models with billet skin. (SLVHXT-822)
  • In stationary quenching analysis, specific setup rules must be followed to avoid errors. Both the profile and quench box must lie within the positive Z quadrant. The solver automatically centers the profile within the quench box; after centering, no part of the profile should extend into the negative Z quadrant. Ensuring these conditions during manual setup prevents the previously reported issues. This will be automated in subsequent releases. (SLVHXT-631)
  • In hollow cone spray quenching, the inner angle of the hollow cone is read and validated to ensure it is nonzero. A typographical error in the code that affected this validation has been corrected in this release. (GIT-2900eb0a)

Friction Stir Welding

Resolved Issues

  • Fixed a solver issue that incorrectly applied a filter function meant for die filling analysis to FSW results, which altered the output during H3D file writing. (SLVHXT-830)