Altair HyperXtrude is a solution adaptive hp-finite element analysis program for modeling complex fluid flow and heat transfer problems encountered in polymer and metal processing. HyperXtrude is specifically developed to address the needs of polymer and metal extrusion process/product design engineers.
Extrusion of aluminum


HyperXtrude simulates material flow and heat transfer by solving the Eulerian/Arbitrary Lagrangian-Eulerian form of the governing equations. HyperXtrude uses residual error estimates and local error indicators to identify the flow domain contributing disproportionate shares of error in the real solution. Using the error information, the mesh in these critical regions can be redefined by either refining the elements (h-refinement) and/or enriching the interpolation order (p-enrichment). HyperXtrude uses a combination of these to provide a near optimal hp-finite element mesh to produce accurate results. The resulting adapted meshes are fully unstructured and anisotropic. HyperXtrude is built on the hp-adaptive finite element kernel ProPHLEX. This kernel provides a high level of modularity and modeling flexibility for creating highly customized niche applications for engineering design analysis. HyperXtrude can be customized for specific user needs.


One of the key benefits in using the adaptive solution algorithm in HyperXtrude is improved engineering productivity by removing the guesswork inherent with mesh generation. This in turn enables the engineers to solve complex problems more efficiently and accurately than possible by conventional fixed grid techniques.

Target Applications

HyperXtrude is particularly suitable for modeling complex nonlinear problems commonly encountered in the process industry. Typical examples include:


The current release of HyperXtrude focuses on modeling incompressible fluid flow and heat transfer problems related to manufacturing processes such as extrusion, polymer melt flow, etc.. The solution algorithm is capable of modeling both low and high Reynolds number (Newtonian and non-Newtonian fluid) flows. Both isothermal and non-isothermal flows can be modeled using HyperXtrude. The non-isothermal feature also allows the user to solve conjugate heat transfer problems.

Analysis Capabilities


Polymer Processing
Extrusion of L-Section Using Profile Die
Film Extrusion Using Fishtail Die.
Extrusion of Square Rod
Profile Extrusion of 
Sheet/Film Extrusion
Flow Inside Maddock Mixing Head
Wire Coating Die Example
Optimization of extrusion dies
Flow inside 
Maddock Mixing Head
Wire Coating Simulation
Design Optimization of 
Extrusion Dies
Metal Forming
Steady State Extrusion of 3D Section
Unsteady Extusion Simulation
Sheet Rolling Simulation
3D Steady State Extrusion 
of Aluminum Section
Time Dependent 
Extrusion Simulation
Steady State Sheet 
Rolling Analysis
Other Applications
Backward Facing Step: hp-finite element mesh
Conjugate Heat Transfer Analysis
Flow and Heat Transfer Inside Electronic Component
Channel With
Sudden Expansion
Conjugate Heat Transfer
Cooling of 
Electronic Component 

HyperXtrude Pricing

The distribution package includes: For more information on product pricing, support, engineering services, and training please  the nearest Altair Engineering office. We look forward to hearing from you.

HyperXtrude Demo

For more information, please call us at (512) 467-0618 or send an e-mail to us at

HyperXtrude Training

This training sessions provides extrusion die design and analysis engineers  with an introduction to Altair HyperXtrude. Concepts of  Adaptive Finite Element Method and their application to the analysis of material flow and heat transfer inside an extrusion die are discussed. This three-day short course covers several HyperXtrude tutorial problems including both 2D and 3D models for steady and time dependent extrusion processes.

Our training room seats eight participants with a dedicated workstation for each individual. The  three-day training course will be held at our facilities in Austin. The schedule for training classes is:
March 2002  6 - 8
July   2002  24 - 26
November 2002  13 - 15

Topics covered:

Course Enrollment Form

For more information on the training course  please  contact the training coordinator.

For information related to accommodation and nearest hotels  please  contact our office administrator Kathy Tischer.


North America: Europe: Asia and Australia:
Altair Engineering, Inc.,
1757 Maplelawn Dr.
Troy, MI 48084-4603
Phone:  248.614.2400
Fax: 248.614.2411
Altair Engineering AB
IDEON Research Park
Scheelev 15, Alfa-Huset
S-223 70 Lund
Phone: +46 (0) 46 286 20 50
Fax: +46 (0) 46 12 87 45
Altair Engineering, Ltd.
Tact No. 4, Bldg. 9F
2-23-12 Minami Ikebukuro
Toshima-Ku, Tokyo 
JAPAN 171-0022
Phone: + 81 3 5396 1341
Fax: + 81 3 5396 1851

Questions, comments or problems regarding this service?

Copyright 1998-2007 Altair Engineering Inc.
7800 Shoal Creek Blvd, Suite 290E, Austin TX, 78757-1031 USA.