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Industry: Aviation In-Cabin Technology
Services Provided: Optical Simulation & Light Pipe Design
Application: USB Charging Interface with LED Illumination
The Challenge
A customer in the aviation sector needed a custom light pipe solution for a USB charging interface used in airplane cabins. The goal:
● Uniform, bright LED illumination for both USB-A and USB-C ports
● Consistent visual performance in all lighting conditions (bright cabin light to darkness)
● Aesthetic integration with illuminated halos that change color based on device status
● Compliance with flame retardancy standards (UL 94 V-0)
● Low part count for ease of assembly and cost efficiency
The Approach
Our optical and mechanical engineering teams worked with the customer’s design group to:
● Simulate multiple LED configurations and surface finishes
● Balance key variables: brightness, uniformity, diffusion, and manufacturability
● Iterate using optical simulation software before physical prototyping
USB-A Light Pipe Design
● Problem: Initial designs showed a brightness uniformity ratio of 6:1 with visible dark spots
● Fix: Replaced base material with diffused polycarbonate, optimized pipe geometry, and introduced surface treatments
● Result: Smooth, consistent illumination and robust performance in production lighting tests
USB-C Light Pipe Design
● Problem: Low brightness in red/blue LEDs due to limited light injection geometry
● Fix: Modified LED count and location; introduced tailored diffusion characteristics
● Result: Bright, color-accurate output matching USB-A performance across all test conditions
The Solution
● Delivered high-performance optical components that met demanding aviation standards
● Enabled consistent visual cues for device status regardless of lighting environment
● Supported a fast prototyping cycle and readiness for scaled production
● Elevated the overall user experience and visual design of the customer’s product line
