RPI ID: 2018-036-401
Innovation Summary: This invention introduces a three‑dimensional (3‑D) optical element that is manufactured using additive processes and contains internal or surface beam‑forming features. The optic accepts incident light on a first surface and emits a shaped beam from a second surface; the emitted distribution (wide, narrow, batwing, or asymmetric) is governed by the engineered feature. Because the features can be embedded as voids or as regions with different optical properties, complex light control can be achieved without secondary reflectors/laminates. The approach supports planar or non‑planar surfaces, opposing or co‑planar faces, and can be paired with LEDs, OLEDs, micro‑LEDs, or lasers. Printing the structure directly enables rapid design iteration, mass customization, and consolidation of parts in luminaires.
Challenges & Opportunities: Key challenges include ensuring print transparency, surface roughness control, and refractive‑index consistency through the build. Material choices must withstand thermal loads from high‑brightness LEDs and remain optically stable over time. Metrology for verifying internal features and in‑situ print monitoring are important to guarantee beam fidelity. Opportunities include custom optics for niche luminaires, on‑demand spare parts, and prototyping of novel beam patterns. The method also opens paths to integrate reflectors, baffles, and diffusers within a single part, reducing assembly cost. Part consolidation can improve environmental sealing and reduce dirt accumulation with optional top layers.
Key Benefits: ✓ Custom beam patterns (wide/narrow/batwing/asymmetric) ✓ Embedded internal structures—no secondary optics required ✓ Rapid iteration and mass customization via 3‑D printing ✓ Potential part count reduction and sealed assemblies ✓ Compatible with LEDs, OLEDs, micro‑LEDs, and lasers
Applications: • Architectural and museum lighting • Task and area luminaires with batwing distribution • Automotive and specialty signaling • Prototype optics for quick A/B testing • Integrated optics for compact consumer devices
Keywords: 3D printed optics; beam shaping; internal structures; batwing distribution; LED luminaire; additive manufacturing
Intellectual Property: US Patent No. 12,352,408