Reinvent The Sky:

eVTOL Air Taxi

3DEXPERIENCE R2023x Speaker Text

January 5, 2023
 Table of Contents
Objective .................................................................................................................................... 1
Scenario..................................................................................................................................... 1
Introduction ............................................................................................................................ 1
Step 1 – 3DEXPERIENCE platform and cloud introduction .................................................... 2
Step 2 – Concept Definition and Validation ............................................................................. 2
Concept Systems Modeling ................................................................................................ 2
Concept Systems Simulation .............................................................................................. 3
Concept 3D Architecture & Simulation ................................................................................ 3

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020

Rotorcraft & eVTOL Vehicle Aerodynamics and Aeroacoustics........................................... 3
Multi-disciplinary trade-off analysis...................................................................................... 4
Reason to Believe ............................................................................................................... 4
Step 3 – On Target Execution................................................................................................. 4
Mechatronics Systems Engineering .................................................................................... 4
Aerospace Composites Engineering ................................................................................... 4
Component Functional Generative Engineering .................................................................. 5
Electrical wire harness engineering ..................................................................................... 5
Battery Module & Pack System Engineering ....................................................................... 5
Portfolio & Product Planning ............................................................................................... 5
Step 4 – Certification & Tracking ............................................................................................ 6
Certification Engineering ..................................................................................................... 6
Step 5 – Planning the Growth ................................................................................................. 6
Assembly Process Engineering & Virtual Build.................................................................... 6
Component Sourcing .......................................................................................................... 6
Conclusion ............................................................................................................................. 7

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 Objective
This demonstration illustrates the Reinvent The Sky industry solution experience for small OEMs.
The example taken is the electric vertical take-off and landing aircraft (eVTOL). About 150 projects
are currently run in the industry, from startups to traditional airframers.

The demonstration goes through several industry process experiences and demonstrates the
development scenario, end-to-end, with cutting edge technologies available already to the
traditional big players in the industry.

Duration: 15min

Scenario

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Introduction
The demonstration is consistently built with the values of the Reinvent The Sky industry solution
experience around four axes:

1. 3DEXPERIENCE platform Public Cloud for agility and collaborative execution:

A cloud business model fits small and medium enterprise needs, offering access to the same
technology available to the largest aircraft makers in the world. Companies also reap the
benefit from having limited IT overhead costs for implementing a new enterprise software.

2. Concept definition and validation to be first on a viable prototype:

The time investment made in the earliest phases turns out to be the winning strategy to
actually save time, by anticipation of problems associated with systematic approach. The final
design requires fewer changes when experts can upfront leverage the simulationexecuted
at different scales, system levels, and disciplines.

3. On target execution:

This is done most times after the detailed engineering end-to-end in a definition of the product
equal to the real one. However, sometimes it can start before the first prototype.

4. Certification to be safe:

To reach the type certificate and be allowed to fly, the eVTOL must demonstrate to certification
authorities that safety conditions are met. Not only is it necessary to prove that required
performance is met, it is also mandatory to justify how the conclusion was built. Therefore,
traceability between regulations, requirements, and design solutions must be enforced as
early as the engineering activities have started. A single source of truth helps companies to
benefit from the digital continuity of data and keeps the design intent clear to certification
authorities.

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 Step 1 – 3DEXPERIENCE platform and cloud introduction
The project manager accesses the 3DEXPERIENCE platform live through a dashboard that
shows the different information he needs for his work. The dashboard can be organized to
source information from different repositories and reveal the relevant information that was
authored withthe specific apps.

The project manager can be aware of the news in the company via 3DSwym communities, as
well as news on the eVTOL market via NETVIBES and topic tracking on the web.

The 3DEXPERIENCE platform is available for all the team members on the Public Cloud for
highflexibility and quick setup. You buy on Monday and use on Wednesday. When you want to
reduceyour workload on some processes, you stop.

The development of an eVTOL involves different people with different skills from different
organizations. One project is put in place to manage the activities and associated deliverables
tokeep the project on track.

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020

Step 2 – Concept Definition and Validation
Concept Systems Modeling
Taking the role of an eVTOL systems architect and before directly jumping to designing the
eVTOL, I must consider all the aspects of the problem to solve, from systems of systems to
systems architecture and simulation.

The systems of systems approach allows me to not miss any aspect of the product definition.

Let’s take the passenger example: going from home to airport by car, arriving in Europe by
aircraft,and taking our eVTOL to reach his office.

Using the best-in-class sysML modeler integrated in the 3DEXPERIENCE platform, we can
definethe missions, objectives, resources, performers, and scenarios for the system of systems
that willbest meet the market constraints.

The operational view is following a UAF standard to model the enterprise, its goals, and the
scenarios corresponding to the problem to solve. Here, our objectives are to reduce CO2
emissions, and accelerate the commute time from work to airport to home. We describe the
configuration that allows these objectives to be met, and simulate the mission at the functional
level. The results of the execution help us define the performance of each actor of the mission
to achieve the overall objectives. By running the simulation multiple times with different
parameters,we identify the best specifications with a trade process.

We conclude this phase with the objectives specific to the eVTOL that will best fulfill the
mission: range, payload, endurance, modularity of usages (taxi, cargo, and emergency
services), and verifying the profitability of the air taxi operations business model.

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 The next step will be to cascade these high-level key performance indicators for the eVTOL
into technical and sub-systems architecture and systems requirements. Here we use the
Cyber MagicGrid methodology to go from operational to functional, logical, and physical
specifications.

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020

Concept Systems Simulation
As part of the eVTOL systems architecture, we demonstrate the use of dynamic models of the
eVTOL to size the batteries. We use the Modelica language to pick behaviors off-the-shelf
from an extensive list of available libraries. For the battery library, we have access to different
fidelity models of battery cells and packs that we easily integrate in the overall architecture.
The batterymodel is executed with the other eVTOL systems in a multi-disciplinary prediction
of the overall behavior and performance of the vehicle on a given mission profile.

Concept 3D Architecture & Simulation

Deep diving into the physical view of the aircraft, we studied different alternatives, all captured
inthe 3DEXPERIENCE platform. How many engines, tilt rotors, or fixed wings? The simulations
willguide us in choosing the best configuration.

The sizing of the eVTOL can start by knowing the mission, loads, and overall 3D architecture
to accommodate the passengers, systems, and equipment. A parametric approach for the first
elements of the structure helps us quickly iterate the design solutions. This facilitates iterations
and enhances productivity for the company, especially in early phases where you want high
flexibility to cope with affecting modifications. You can explore more concepts at the same
time.

Rotorcraft & eVTOL Vehicle Aerodynamics and Aeroacoustics

Noise is one of the primary constraints given in the city environment. As much as possible, to
mitigate project risks, the team would like to anticipate which solutions to develop and which
to avoid very early in the design.

Minimizing noise is critical in those situations where the eVTOL will operate overhead in cities.
We study the impact of noise in the city with aeroacoustics simulation in various operating
conditions.

Aerodynamics simulations will compute the external loads applied during a specific mission.
These results will feed the structural simulation to check if the eVTOL will handle such
external
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 forces according to the current design. We also look at the fuel efficiency based on the
performance of the rotors and lifting devices.

These are some examples of the built-in simulation capabilities of the 3DEXPERIENCE platform
that can feed a multi-disciplinary trade-off analysis.

Multi-disciplinary trade-off analysis

The investment done by the different experts will be leveraged in multi-disciplinary trade-off
analysis process to do a multi-disciplinary optimization and alternatives study. We bring these
simulations together inside an orchestrated process.

By scoring which KPIs (e.g., noise, flight range, or manufacturability) are the most important for
our product, the tool will explore thousands of configurations and simulation results, and rank the
best compromise that will best meet the mission and program objectives.

Then when the best solution is found, we have enough confidence that this is the configuration to

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020

move forward into development. To finance this effort, companies may look for a business angel.
How do we convince them?

Reason to Believe
We are displaying the journey of a typical customer that needs to be home for supper after
traveling between clients. The eVTOL will wait for him at the airport and will land in his garden.

In the Reason to Believe process, the 3DEXPERIENCE platform is the best platform to create
storytelling around the concept. People can immerse themselves in a lifelike scenario where the
concept is demonstrated to the different stakeholders. This is realized with minimal effort by
reusing all the 3D assets and behaviors from engineering. This way, you can share the status of
your concept with visual experiences, leveraging the virtual twin.

Step 3 – On Target Execution

Let’s recap: we have specified what the concept should be, and we have the proper funding to
proceed. The next step is to do a more detailed design and plan for a prototype.

Mechatronics Systems Engineering

We put in place a multi-disciplinary team that will work on their specific expertise around a single
repository and DMU, starting with mechanical design.

The 3DEXPERIENCE platform best-in-class kinematics and dynamics tools help to build
mechanisms right the first time.

Kinematics results can be easily shared in a web widget with the entire company.

Aerospace Composites Engineering

Specialized disciplines, such as composites design, can also be managed in the 3DEXPERIENCE
platform for composites engineering. CATIA Composites allows you to enhance the composites
engineering definition and to take into account manufacturing constraints at the earliest stage.

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 There is a digital continuity between composites, mechanical, and the associated
simulations so that we can quickly iterate. Manufacturing is in the loop to assess the
manufacturability of what is being designed.

Component Functional Generative Engineering

Now we promote a different approach. We reverse the CAD and FEM to make the simulation
drive the design. For part design, let me show you a topology optimization example in
componentfunctional generative engineering process.

According to the functional constraints and load cases, the part is automatically optimized to
fit.

Then, depending on the KPIs such as weight or cost, a trade-off is automatically available
to select the best alternative depending on the manufacturing methods: additive
manufacturing as well as machining and molding.

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020

Electrical wire harness engineering
One of the greatest challenges for eVTOL is the electrical and battery design. As the
3DEXPERIENCE platform is a multidisciplinary platform, digital mock-up can incorporate
more information such as electrical wiring harness.

Electromagnetic Engineering
In the domain of Electromagnetic System Engineering and Optimization, the
3DEXPERIENCE harnesses the capabilities of CST Studio Suite, a powerful
electromagnetic simulation tool. This tool facilitates the thorough design, simulation, and
optimization of diverse electrical components, spanning antennas, PCBs, cable wire
harness systems, sensors, and more.

The initial phase involves either importing the CAD model directly into CST from the
3DEXPERIENCE, including all relevant materials and model characteristics, or constructing
the model within CST itself, based on its complexity.

Subsequently, through the utilization of different solvers, the simulation runs, providing a
detailed visualization of various aspects of electromagnetic waves within the application.
This includes understanding the behavior of antennas, evaluating factors like range,
efficiency, effectiveness, and overall performance.

For applications requiring adherence to specific industry standards, CST proves invaluable
in optimizing the application. This optimization may entail adjustments to the application's
geometrical characteristics to meet predefined goals. Applications for communication and
detection systems, compatibility and interference between different systems, emission
radiation, and potential bioeffects on humans fall within the purview of this optimization
process.

The platform's robust capabilities enable the seamless integration of the updated
application, complete with all its refined characteristics, into the overarching system. This
streamlined approach ensures a cohesive and optimized electromagnetic system that aligns
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 Video 1: Antenna Workflow
This video showcases an Antenna Array, which is typically used for communication and
detection applications such as GPS tracking, and autopilot communication with the drone.
You can see how CST can be utilized to design the antenna array, then depending on the
required gain or performance, it will modify the physical geometry of the array to achieve
that point. After which, you will be able to build the entire antenna array and use the
integration of the 3DEXPERIENCE to apply this updated and optimized antenna array to
your application.
Video 2: Antenna Placement
Now that optimized the antenna array, you can see how CST will help in aligning it into the
entire aircraft. With this you can guarantee the most effective results. It will also allow you
to view the changes in performance of the antenna performance when you change the
placement of the antenna. You can see here the Smith Chart which indicates on the
performance given on the location and whether there are any blocking points in the body of
the aircraft.
Video 3: Lightning Strike
Another area of interest of the aircrafts would be ensure and verify the safety of the electrical
components of it. This is where you may also utilize CST to understand the points of the
highest potential when lightning strikes. With this, you can change your build accordingly in
terms of materials or electronic protection systems. This is also heavily used to have
aircrafts certified with the industry standards of aerospace.

Battery Module & Pack System Engineering

3DEXPERIENCE multi-physics tools allow multilevel battery optimization, battery materials
optimization, battery cell engineering, and battery module and pack engineering. It is
important toconsider the battery discipline at different scales. We will study it from atoms to
systems.

The first step is to size the batteries and place them within the aircraft. This impacts the
center ofgravity and maneuverability of the aircraft. It is necessary to iterate between physical
location andexpected performances of the battery and decide how much weight to embark.

As we develop the pack itself, we need to take care of the thermal management and simulate
thecooling flow within the pack. We need to secure structural integrity to avoid internal short
circuitsin case the battery is under load.

Sometimes the innovation stands on the battery materials used: solid state, lithium ion, or air.
Thiscan be modeled and simulated at a micro-scale level via the BIOVIA Materials Studio.

Portfolio & Product Planning

When you accumulate knowledge on your product, you can put in place a family of products
or product lines to accommodate more customer needs in the portfolio and product planning
process. The 3DEXPERIENCE platform is also the tool to manage all the product lines and
features.

The product engineer or marketing department can create configurations to manage product
evolutions, variants, or options. A company’s variants and options catalog can be created, as
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 wellas rules to manage effectivities between the variants.

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 Product configurations can be created to capture a specific version of the product. In this example,
a product configuration has been created for an air taxi delivered to the city of Paris.

Here, as the autopilot option has been selected, the CTOL variant is not compatible, and therefore
isn't allowed.

To increase the profitability of the eVTOL business, we have created three different usages
corresponding to three different cabin modules. By switching from air taxi to cargo and emergency
services, we maximize the use of the eVTOL and our chances of having a successful product in
the market.

The design follows the configuration of the product. Every product configuration will correspond
to a mock-up that is accessible to every stakeholder in the platform.

Step 4 – Certification & Tracking

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020

Certification Engineering
Here, a certification plan has been created with a work breakdown structure capturing the different
team members to involve and setting the deliverables expectations for everyone.

The traceability between requirements and design solution justifies to the authorities that the
regulatory requirements are fulfilled and implemented. This is an end-to-end traceability, from
requirements to test cases, design, and manufacturing.

It is possible to be directly connected to the FAA or EASA website to automatically be aware of

and retrieve the applicable up-to-date regulations. We, therefore, know the impacts on the
certification deliverables, test cases, and product structure if a new regulation amendment has
been published.

Intensive use of virtual simulation demonstrates to certification authorities that our design exceeds
the requested performance in terms of noise, bird strikes, lightning strikes, vulnerability, systems
and structure failure, and overall safety. These early simulations will positively impact the
engineering. If the certification process is not anticipated, huge design modifications will reduce
the time to prototype and time to certification.

Step 5 – Planning the Growth

Assembly Process Engineering & Virtual Build
In order to commit to a given production rate, the manufacturing engineer will be able to simulate
manufacturing processes, such as additive manufacturing and milling, and optimize the
manufacturing operations and factory layout. Similar to certification, we promote an early
manufacturing engineering to influence the engineering and reduce time and cost.

Component Sourcing
For specific or overloaded manufacturing operations, the 3DEXPERIENCE Marketplace can put
companies in touch with a list of qualified suppliers. It is possible to have quick access to suppliers
in the same location with the rights tools and expertise. As in any marketplace, you fill your

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 shopping cart knowing the quality, cost of production, and shipment delay. 3DS keeps the list up-
to-date and will take care of the transaction.

Conclusion
We went through different industry process experiences to define, develop, and manufacture our
new eVTOL that can Reinvent The Sky. Many different expertises were needed and yet we used
the 3DEXPERIENCE platform from end-to-end. We allowed seamless collaboration between the
teams without any model transformation. This led to:

 cutting the time to prototype by 50%

 reaching certification on time
 a unique final customer experience
 agility with cloud

© Dassault Systèmes | Confidential Information | 1/5/2023 | ref.: 3DS_Document_2020