3D printed plano-freeform optics for non-coherent discontinuous beam shaping
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The design, fabrication, and characterization of freeform optics for LED-based complex target irradiance distribution are challenging. Here, we investigate a 3D printing technology called Printoptical® technology in order to relax or push forward both the fabrication limits and LED-based applications of thick freeform lenses with small slope features. The freeform designs are carried out with an assumption of small-sized LED source using an existing point-source-based Tailoring method, which is available in the semi-commercial software. The numerical methods of the designs are characterized by ray-tracing software. The irradiance patterns of the 3D printed freeform lenses are promising considering the average shape conformity deviation of around ± 40 µm and center area surface roughness around ± 12 nm, which is to our knowledge by far the best result reported for 3D printed freeform lenses with a thickness greater than 1 mm. Applications of freeform lenses with discontinuous target irradiance distribution patterns are expected in eco-friendly energy efficient lighting such as in zebra-cross lighting.
KeywordsFreeform optics Non-imaging optics 3D printing Light-emitting diodes
This work has been financial supported by the Finnish Funding Agency for Technology and Innovation (TEKES) through the project number 247126-4524. The work also supported by the Academy of Finland (Grant 285880). The authors thank Prof. Youri Meuret for his fruitful ideas and discussions on freeform optics, and acknowledge Jani Tervo, Henri Partanen, Pertti Pääkkönen, Tommi Itkonen, Markku Pekkarinen, Ville Kontturi and members of the 3D printing optics group at UEF for their valuable suggestions and help.
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