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Case Study

Optimizing Aircraft Illumination With Ansys Optical and Lighting Simulation Software at Embraer

“By validating our designs digitally early on, we can anticipate development risks, identify issues before even creating mockups, and move to the physical phase with a high degree of confidence. This approach reduces costs and prevents rework, cutting down engineering time without compromising product quality.” 

-Marcio Ferraz Gobato, Senior Principal PDE - Interiors, Cabin Systems and IFEC - Core Engineering Department / Embraer

For leading aircraft manufacturer Embraer, creating physical mockups of aircraft lighting systems and interior cabin appearances is a part of its development process. Anticipating lighting design issues even before a physical mockup is assembled can prevent unnecessary rework costs and schedule impacts. With these challenges in mind, the company began researching applications to address these critical issues and enhance its development process.

With the addition of Ansys optical tools, Embraer was able to optimize its design workflow and demonstrate the effectiveness of simulation for validation purposes to regulatory agencies. The company plans to expand the use of these tools across multiple lighting applications, including exterior and interior lighting, lighting effects appearance, and interface to virtual reality. These capabilities enable engineers to validate the readability of information systems inside the cabin, enhancing both design precision and compliance.

cabin emergency lighting system

Cabin emergency lighting system modeling and simulation

Challenges

Embraer sees opportunities in the design and validation of its aircraft illumination systems. The use of digital simulation tools enhances flexibility to explore design variations and optimize efficiency. Given the stringent certification and appearance requirements, Embraer sought a more efficient solution to optimize designs and reduce development and certification risks. 

embraer executive cabin virtual mockup

Embraer executive aircraft cabin virtual mockup using Ansys Speos software for optical simulation

Engineering Solutions 

Embraer selected Ansys Speos software to support the design of its aircraft illumination systems. By leveraging optical simulation, Embraer reduced development risks, enhanced the design workflow, and opened the opportunity to discuss with authorities the viability of using simulation for certification purposes. The tool was utilized for applications including cabin emergency lighting, external lighting (such as anti-collision and landing lights), and appearance analysis (for executive jets, cabin sign readability, and eVTOL interiors). 

virtual cabin environment in speos

Virtual cabin environment in Speos software

Benefits

By validating designs digitally, Embraer reduced development risks and created opportunities to accelerate the development timeline for aircraft illumination systems. Optical simulations enable thorough testing of design variations, reducing rework costs and engineering time while ensuring the highest product quality and compliance with lighting requirements.

“The eVTOL market, being under development, is already a project challenge by nature. For the external lighting project, different solutions are required for various flight phases and trajectories,” Embraer product development engineer Marcela Salomão says. “Shadows and dimensions of the vehicle itself bring a completely new perception. Some references from traditional aircraft are not directly applicable to an eVTOL vehicle. Therefore, simulations are the main tool for developing an effective project.

“Speos software allows realistic simulation with the Human Eye Sensor [capability], supporting assessments of what best suits the shape of the vehicle, complying with all certification requirements, and providing an excellent experience for pilots and operators.”

high fidelity product appearance analysis

High-fidelity product appearance analysis