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Customer challenge
Light distribution, colour temperature and material influences play a decisive role in the development of modern optical systems, such as lighting or sensor systems. Even small deviations in geometry or surface quality can severely impair functionality.
Our customer faced the challenge of validating a complex optical system early in the development process – without costly physical prototypes. They were looking for a solution to precisely simulate and optimise the behaviour of light sources and lenses under real-world conditions.
Would you also like to validate your project at an early stage? Find out what we can do for you!
Our solution
A detailed digital model of the optical system was created using ANSYS SPEOS optical simulation software. We analysed the propagation, distribution and composition of light, took material and surface properties into account, and investigated the influences of production tolerances.
This allowed critical issues to be identified and corrected during the design phase – long before the first prototype was manufactured.
System properties and performance features
Performance features
- Ray tracing in illumination systems
- Simulation of production tolerances
- Optimizer for optical design
CAD-integrated
- Parametric model construction
- Variant creation (geometry/material/surfaces)
- Geometry optimisation
Analysis
- Insights into optical systems that can only be carried out to a limited extent in reality
- Evaluation and representation of light paths
- Detection of scattered/interfering light
- Assessment of production deviations due to component and position tolerances
- Evaluation of brightness distribution and homogeneity
Results and customer benefits
Virtual validation of the optical design enabled a significant reduction in development time and costs. The precise digital twin allowed sources of error to be identified early on and design adjustments to be implemented in a targeted manner.
- Shorter development cycles
- Reduced prototype costs
- Higher product quality
- More efficient coordination between design and manufacturing
Optical simulation proved to be a crucial step in bringing a market-ready product to market faster and with less risk.