Simulation tool tackles vehicle cabin noise before prototypes are built
Electric vehicles (EVs) have transformed modern mobility. Without the rumble of internal combustion engines, drivers expect a serene cabin experience. Yet this silence has revealed a new challenge: even the smallest acoustic leaks—gaps, holes, or imperfect seals—can let in road and wind noise, disrupting the calm.
For engineers working in NVH (Noise, Vibration, Harshness), acoustics, and Body-in-White (BIW) design, these leaks are notoriously difficult to detect early in development. Traditional methods rely on physical prototypes and smoke tests, often catching problems too late. Enter Elsyca LeakageMaster, a simulation-driven solution designed to identify and quantify acoustic leakage paths long before prototypes exist.
Simulation-driven silence
Elsyca LeakageMaster enables engineers to evaluate CAD or STL geometry early in the design cycle, making cost-effective changes before production. Key features include:
- Early design assessment: Spot leaks directly from digital models.
- Automatic plug creation: Virtually seal manufacturing holes to test strategies.
- Acoustic path computation: Map sound trajectories from exterior to cabin.
- Quantifiable output: Rank leakage paths by size and impact for prioritisation.
- CAD integration: Export results in CAD-compatible formats for seamless collaboration.
This proactive approach shifts cabin noise control from reactive testing to predictive design, helping manufacturers deliver the quiet ride consumers expect.
Mitsubishi Motors case study
Mitsubishi faced a common issue: CAD models overloaded with detail made it nearly impossible to identify all potential leaks. By deploying Elsyca LeakageMaster, engineers automated detection and visualization, achieving a measurable 1 dB improvement in cabin quietness across the full frequency range.
The tool provided quantitative data for risk assessment, visual feedback for design teams, and simulated results that matched physical blower door tests—validating its accuracy. This case highlights the value of moving from late-stage fixes to early-stage prevention.
What’s new and next
Elsyca continues to refine LeakageMaster with faster model iteration, improved post-processing, and parametrised stop planes. A new meshing algorithm and hole solver enhance the detection of small leaks and improve robustness against raw CAD errors.
To showcase these advances, Elsyca offers an on-demand webinar hosted by Romain Baudson, Director of Product Operations, who brings over a decade of NVH CAE expertise. The session demonstrates how simulation-driven leak detection can transform workflows for NVH engineers, CAE analysts, and BIW designers.
Why it matters
In a market where silence is the new luxury, EV manufacturers cannot afford to let cabin noise undermine customer expectations. By identifying leakage paths directly from digital models, visualising sealing strategies virtually, and reducing reliance on late-stage physical tests, Elsyca LeakageMaster helps teams improve acoustic performance faster and more cost-effectively.
HAH Software, Elsyca’s consulting and deployment partner in the UK and Ireland, supports local adoption of this technology, ensuring manufacturers can deliver the quiet, premium cabin experience that defines the EV era.