In the race toward electrification, automotive OEMs face mounting pressure to reduce development timelines while managing increasing architectural complexity. Gearbox housings remain as one of the car components that must now respond to continuous system evolution: changes in electric motor packaging, inverter positioning, new cooling layouts, shifting loadpaths... Design engineers are on the front line, responsible for delivering parts that fit evolving assemblies, meet performance targets, and comply with casting-specific manufacturing rules. However, fragmented workflows and rigid CAD processes make this task time-consuming and error-prone.

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This case study focuses on the design of a castable gearbox housing for a next-generation hybrid vehicle, showing how the integration of performance and manufacturability constraints within an automated workflow allows engineers to deliver more reliable, and production-ready results 10 times faster, even when system definitions change mid-stream.