Services · Light development from a single source
From analysis to series production

Services for LED products – light development from a single source

Eight building blocks, individually or as a complete package: lighting issue analysis, concept, CAD design, light simulation with Ansys SPEOS, tolerance analysis, prototype & measurement, architectural lighting and SPEOS training.

Ansys SPEOSCATIA · NX · SolidWorksInitial assessment 48 hNDA possible
Fundamentals in the industry wiki (German): Light in the product · Light simulation
Light ring before optimisation: too dark at the topLight ring after optimisation: uniform
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BEFOREAFTER
Light ring before and after optimisation – solved in simulation before any tooling exists.

Choose your starting point

Three routes to the perfect light pattern – every package can be extended with individual building blocks. Scope and price after the free initial assessment.

Assess the current state
QUICK CHECK
Solve a lighting issue

For faulty prototypes and series parts

  • Analysis based on photo and CAD
  • List of causes and measures
  • Optional: simulation of the solution
Initial assessment in 48 h
Most popular
DEVELOPMENT
Complete light system

From idea to released design

  • Concept comparison and LED selection
  • CAD design of light guide and optics
  • SPEOS simulation and optimisation
  • Tolerance analysis for series production
Everything from a single source
SERIES & TEAM
Secure & enable

For series launch and in-house expertise

  • Prototype, measurement and correlation
  • Series support and complaints
  • SPEOS training and coaching
Ongoing or as a workshop
In short: Development covers creating the CAD data of the light system, optical analysis and optimisation with light simulation, tolerance assessments and integration into the main product. The optimisation targets defect-free colour display, high brightness and perceived evenness (uniformity).

All service building blocks in detail

Light ring with non-uniform light pattern before optimisation
BUILDING BLOCK 01

Lighting issue analysis

Your prototype or series part shows hotspots, stray light, colour fringes or visible LED dots? I find the cause – often from a photo and CAD alone – and show the most effective change, usually without a new tool.

  • Evaluation of the light pattern by colour, uniformity, viewing angle and brightness
  • Root cause analysis: LED position, holder, material, tolerances
  • List of measures, on request with simulation of the solution
From practice: Stray light of a status LED reduced by 79 % (116 → 25 cd/m²)
You providePhoto of the light pattern, CAD (STEP), LED datasheet
You getInitial assessment in 48 h, root cause report with measures
Luminance distribution of a backlit surface in a concept comparison
BUILDING BLOCK 02

Concept & light system design

The light pattern requirement defines the light system. I select the LED, light guide, diffuser or reflector concept to suit installation space, cost and design and compare variants directly.

  • LED selection (top LED, side LED, RGB) and positioning
  • One-, two- or three-piece light systems compared
  • Feasibility, efficiency and cost evaluated early
From practice: Vehicle light module: uniformity increased from 40 % to 87 %
You provideRequirements, installation space, design brief
You getConcept comparison with evaluation and recommendation
Simulated RGB light bar with colour mixing
BUILDING BLOCK 03

CAD design of optical parts

Light guides, outcoupling structures, lenses, diffusers and holders – designed for manufacturing with draft angles and tolerances, in CATIA V5, NX, SolidWorks or SpaceClaim.

  • Light guide geometry: cross-section, radii, outcoupling structures
  • Holders, reflectors and masks against stray light
  • Design for injection moulding, including 2K light guides
From practice: Toy button: brightness from 300 to 610 cd/m² thanks to an optimised diffuser
You provideSurrounding data, material, manufacturing process
You getNative CAD data, STEP, notes for the drawing
False-colour luminance of an LED matrix in the SPEOS simulation
BUILDING BLOCK 04

light simulation with Ansys SPEOS

The core: luminance, uniformity, colour, efficiency, stray light and viewing angle are evaluated and optimised virtually – before any tooling exists. So you need fewer prototype loops.

  • Luminance (cd/m²), illuminance (lx), colour coordinates
  • Optimisation of outcoupling, LED spacing and diffuser
  • Visualisation of how people perceive the light pattern
From practice: Charge indicator: evenness increased from 37 % to over 90 %
You provideCAD, LED ray file or datasheet, material data
You getLight report with false colours, key figures and recommendation
Simulation of a backlit symbol with tolerance assessment
BUILDING BLOCK 05

Tolerance & series analysis

LED bins, position and material tolerances are checked by simulation so that the light pattern stays consistent under real production conditions.

  • Worst-case assessment of LED position and part location
  • Influence of LED binning and material batches
  • Robust measures before series launch
You provideTolerance chain, LED binning, material details
You getTolerance evaluation and robustness measures
Simulated illumination of a wall washer
BUILDING BLOCK 06

Prototype, measurement & correlation

On request, I supply prototypes and series parts for light guides, optics and housing parts through a reliable partner network. Measurements are taken on the real part and correlated with the simulation – with known optical data, agreement exceeds 95 %.

  • Prototypes via partner network
  • Measurement of luminance and colour on the part
  • Correlation measurement ↔ simulation
From practice: Simulation 399 cd/m² vs. measurement 410 cd/m² – less than 3 % deviation
You provideReleased development state
You getPrototypes, measurement report, correlation
Simulated façade lighting with amber light
BUILDING BLOCK 07

Luminaires & architectural lighting

Test illumination, illuminance, luminance and LED performance data without building samples. Luminaires can be moved virtually – you see the result immediately in the simulation.

  • Façades, wall washers, linear lights and downlights
  • Lux and luminance maps, glare
  • Variants of position, distance and optics
You provideFaçade or room, luminaire data
You getLux and luminance maps, variant comparison
Luminance distribution of a light ring in the simulation
BUILDING BLOCK 08

SPEOS training & coaching

As a SPEOS trainer, I get your team started with light simulation – from the basics to evaluating your own projects, on site or remotely.

  • Basics of lighting technology and light simulation
  • Working on your own parts
  • Coaching during ongoing projects
You provideYour question, your own data if available
You getTraining and project coaching

What clients say (Google, 5.0 ★)

Google review for TKLEngineeringGoogle review for TKLEngineering
Thomas Kümpfel, light development engineer

Which service fits your project?

Send project information or a photo – initial assessment within 48 h, NDA possible. I reply personally.

Send project information →By email
250+series projects
8service building blocks
> 95 %agreement simulation ↔ measurement
48 hinitial assessment