3D Printed Biconvex Lens Array for Customized LED Lighting
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Solution Overview
Problem
Conventional methods for producing optical components, such as beam shaping and color mixing optics for LED luminaires, are costly and limited in their ability to produce complex components, particularly those requiring integration of multiple materials or customization, and struggle with achieving specific optical properties.
Innovation Solution
The method employs 3D printing using fused deposition modeling to create a stack of biconvex cylinder lenses, allowing for customization and integration of materials with varying optical properties, enabling precise control over light manipulation and beam shaping through selection of printing materials and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods (extrusion, injection molding) are used to produce optical components, then production is possible, but tooling costs are high and customization is limited
Solution Approach 1:
The patent changes the manufacturing parameters from conventional extrusion/injection molding to 3D printing technology. This enables variable geometric parameters (lens curvature, thickness, shape) to be customized without new tooling, directly resolving the contradiction between production feasibility and customization capability
Solution Approach 2:
The patent uses 3D printing to create physical copies of custom optical designs directly from digital models. This eliminates the need for expensive master molds and tooling while enabling full customization of optical components, addressing both production feasibility and adaptability requirements
2Ease of manufacture
If conventional methods are used, then production is possible, but integrating multiple materials into a single component is difficult
Solution Approach 1:
The patent merges multiple materials with different optical properties into a single integrated optical component using 3D printing. Different regions of the component can be printed with materials having varying refractive indices, absorption characteristics, or scattering properties, all in one manufacturing process, thus resolving the contradiction between production capability and material integration complexity
Solution Approach 2:
The patent employs composite materials with different optical properties within a single 3D printed component. By selecting appropriate materials for different regions, the component achieves complex optical functions (beam shaping, color mixing, diffusion) that would be difficult to achieve with homogeneous materials or require multiple separate components
3Ease of manufacture
If conventional methods are used, then production is possible, but producing complex optical components with specific optical properties is limited
Solution Approach 1:
The patent uses 3D printing to precisely control geometric parameters (lens curvature radius, thickness distribution, shape) with high manufacturing precision. The digital model allows exact control of optical surface profiles and internal structures, enabling specific optical properties (focal length, beam shape, scattering characteristics) to be achieved with precision that conventional methods cannot provide
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of optical components with tailored optical properties and shapes, offering extensive design flexibility and cost-effectiveness, capable of achieving complex light manipulation tasks that conventional technologies cannot, such as color mixing, diffusing, and focusing light.
Implementation Method 1
The method employs 3D printing using fused deposition modeling to create a stack of biconvex cylinder lenses
Implementation Method 2
Each layer is a biconvex cylinder lens having an optical axis perpendicular to a stacking direction of the stack
Data Source
AI summary
An illumination device includes at least one light source and at least one optical component formed by a stack of at least two biconvex cylinder lenses, each lens having an optical axis perpendicular to a stacking direction of the optical component. The optical component is manufactured using a 3D printing process using fused deposition modeling.