Technology and Craftsmanship

technology and craftsmanship

Technology Throughout

Embraer has built itself into one of the leading manufacturers of business, commercial and defense aircraft by adapting the latest technologies to meet the rigorous demands of high utilization and low operating costs that set our aircraft apart from their rivals.

Using cutting-edge virtual-reality tools throughout the design and development process, Embraer aircraft establish new standards in performance and comfort, redefine lifecycle expectations and maintain the highest levels of quality control for each and every component.

This commitment to technological advancement is tangible at every level, be it in the precision of our cockpits, the quality of our production line, the quiet of our cabins or the efficiency and ease of our maintenance procedures. All of this is conducted with a respectful appreciation of aviation’s past successes, which provides us the knowledge and wisdom to incorporate only the best - rather than simply the latest - ideas into each of our designs.

Technology in Aircraft Design

In the conceptual phase of aircraft design, Embraer applies Computational Fluid Dynamics - commonly referred to as CFD - which uses numerical methods to simulate and analyze air flow, and calculate the forces upon the virtual aircraft. The digital aircraft model is adjusted until design goals are optimally achieved.

A scaled-down model of the aircraft is then submitted to a wind tunnel test campaign, where measurements of aerodynamic forces are collected with an array of instrumentation to derive performance data.

Computational Fluid Dynamics - Corporate Jets

Technology in Aircraft Development

Each aircraft is digitally designed with CATIA V5, the industry’s leading product life-cycle management system. Over 100 suppliers join several hundred Embraer engineers for the Joint Definition Phase, or JDP, where the Virtual Reality Center becomes the hub of critical design reviews to ensure seamless component and systems integration. The result is a production aircraft design.

Throughout the JDP, Embraer and engineers from our suppliers conduct spatial analyses of systems and components to maximize the efficiency of the aircraft design, the components, systems performance and maintainability throughout the aircraft’s life cycle.

Technology in aircraft development
technology and craftsmanship

Technology in Aircraft Manufacturing

The main structures of an aircraft are built with an automated riveting machine. But before a single rivet is put into place, the fabrication of all primary parts has already been simulated in a 3D digital manufacturing system with virtual numeric-control software. Based on simulation results, design details are honed to maximize both quality and machine performance.

Before any assembly line tooling is made, their design has already been evaluated in the virtual simulator. The fabrication of primary parts is also simulated to ensure component production viability and optimization analyses. Quality control applies laser and ultrasound technology.

A paperless assembly line relies solely on real-time data to ensure process, cycle, design and quality conformity throughout the aircraft production.

Technology in Aircraft Materials

Metallic and composite materials excellence are both priorities for Embraer. The Phenom jets were the company’s first aircraft to have primary parts in composite material, such as carbon fiber. Composites are cured in autoclaves, which deliver the highest quality results, and provide weight reduction and greater resistance against corrosion and fatigue. About 16% of the Phenom 300’s structural weight is comprised of composite material, including the nose and vertical stabilizer.

Embraer is also renowned for its expertise in aluminum super forming. For example, the rear fuselage of the Phenom 300 curvature favors the flow of air around its engines. Although this part could also be manufactured with composite material, Embraer opted for aluminum to maximize aircraft performance as well as maintainability.

Embraer’s Centers of Excellence in Metallic and Composite Materials are located in Évora, Portugal, where research and development of these materials have led to enhancements in aircraft design.

Technology and Business Aircraft
technology and craftsmanship

Technology in Aircraft Testing:
Iron Bird, Flight Simulator, Environmental Control Systems

Long before a new aircraft takes flight, well over 20,000 hours of systems testing is conducted in rigs that replicate the aircraft’s avionics, electric and hydraulic systems. These rigs are integrated, forming the Iron Bird.

The Iron Bird houses the flight deck, which serves as the flight simulator for test pilots to carry out thousands of flights to rigorously test systems in all phases of flight. Real data from aircraft flight tests are fed into the Iron Bird simulator to enhance the precision of the aircraft’s behavior and response. Upon aircraft certification, this data is also used in flight training simulators, maximizing the realism of aircraft simulation.

Premium comfort is also a key driver of Embraer’s business aircraft design. For the best flight experience, passengers’ ergonomic comfort is complemented with the Environmental Control System (ECS), which gradually pressurizes the cabin as the aircraft ascends to cruising altitude. Throughout the flight, the ECS ensures that the flow, the temperature and the quality of the air in the cabin is as comfortable as a spring day on a mountain top.

Technology in the Cabin – IFE, Mobile

The in-flight entertainment system consists of a high-definition video system, 5.1 surround sound and multiple audio and video input options. Internet connectivity and integration with all modern entertainment, video game systems, mobility and cabin management system are at the passengers’ finger tips, whether on a mobile phone, tablet or iPad.

Technology in the Cockpit – FBW, most advanced Rockwell Collins avionics suite, HUD and EVS

The Legacy 500 is the first business aircraft in the midsize segment with full fly-by-wire technology, featuring side stick flight controls, which enhances flight precision and efficiency, and ensures a smooth flight experience for passengers. The state-of-the-art Rockwell Collins Pro Line Fusion avionics suite with four 15.1-inch high-resolution LCD displays is capable of paperless operations, with graphical flight planning, digital charts and maps, and synthetic vision system. 

Legacy 500 biz jet flight deck

The Embraer Enhanced Vision System (E2VS) features a Head-Up Display (HUD) with embedded synthetic and enhanced vision capability.

technology and craftsmanship

Technology in Support – FlyEmbraer & AHEAD

FlyEmbraer is the single point of reference for Embraer’s customer support solutions, from technical publications to training and field support, parts and maintenance. Operational information is critical for customer support, both for troubleshooting and for the maintenance schedule. Technical publications are also accessible to customers and to field support technicians to ensure prompt and effective aircraft service.

To expedite the availability of flight data to each area of support, Embraer developed AHEAD (Aircraft Health and Advanced Diagnostics), a system that uses flight data to drive all support areas, from updating the maintenance schedule to dispatching field support technicians and parts for aircraft inspection, troubleshooting or repair.

In the Legacy 500, the Rockwell Collins avionics system seamlessly connects with AHEAD to provide flight data in real time or upon landing.

Aerospace Technology Heritage

While Embraer Executive Jets is completing only its first decade, the technology we see in each new aircraft carries the DNA inherited from the company’s 45-year expertise in commercial and defense aviation. The fly-by-wire technology introduced in the Legacy 500 and Legacy 450 stems from Embraer’s first experience with fly-by-wire in the AMX fighter project, in the late 1980s. 

The most advanced fly-by-wire is now returning to Embraer Defense and Security in the new KC-390 airlifter, and it will soon be implemented in the next generation of Embraer Commercial Aviation’s E-Jets E2.

Legacy 500 Corporate Jet