For a clear overview and assessment of the results of all the calculated variations, the Heunisch experts used a scatter diagram. In this diagram, the different bar configurations were marked using colors and directly visualized regarding the defined optimization targets.
The best solutions, showing air entrapment below a defined limit, included two variations with two bars and one variation with three bars. The 3-bar-design also showed minimal air contact of the metal.
Compared to the initial design without the bars, the level of air entrapment was cut in half with this new layout. The castings eventually produced with the optimized 3-bar-design were within the specification, making the production of the exhaust manifold a technical and economic success right from the start.