ABSTRACT
We present the development of a compact (about 1.3 × 2.0 × 20 mm3) freeform optical lightguide for sensing applications, from the conceptual design to the fabrication through injection molding. The design of the optic is based on the flow-line method from Nonimaging Optics, which allows the desired optical functionalities (45° half-acceptance and 40° beam steering) while meeting particularly tight mechanical and geometrical constraints. An extensive analysis of the effects of fabrication parameters on the performances demonstrates the importance of minimizing the fillet radius. This requisite inspired a special procedure for designing the mold, which is built as a "3D puzzle" assembly of separate pieces, each one dedicated to one specific side surface of the lightguide. This technique enables uniform optical quality on all the optic's surfaces and removes the need of a fillet radius in the mold. At present, the first lightguide prototypes have been fabricated; after the coating phase, they will be ready for the validation stage.
ABSTRACT
Multi-chip and large size LEDs dominate the lighting market in developed countries these days. Nevertheless, a general optical design method to create prescribed intensity patterns for this type of extended sources does not exist. We present a design strategy in which the source and the target pattern are described by means of "edge wavefronts" of the system. The goal is then finding an optic coupling these wavefronts, which in the current work is a monolithic part comprising up to three freeform surfaces calculated with the simultaneous multiple surface (SMS) method. The resulting optic fully controls, for the first time, three freeform wavefronts, one more than previous SMS designs. Simulations with extended LEDs demonstrate improved intensity tailoring capabilities, confirming the effectiveness of our method and suggesting that enhanced performance features can be achieved by controlling additional wavefronts.