Feature: LEDs


• What LED or LEDs should you use? • How do you meet efficiency targets? • What mechanical constraints need to be considered? • How will the control electronics be realised? • What are the aesthetic and optical requirements? • How do you meet the target product cost? Our experience at Forge shows that, by tackling these


decisions together and iteratively, every element of a custom LED product can be optimised to deliver exceptional performance and innovation. When designing your product, decide which LED or LEDs to


use. Te design process itself combines simulation and hands- on experimentation, relying on a range of disciplines – from optical physics and mechanical engineering to electronics and production design. We begin with mathematical modelling, using soſtware to


trace the path of light rays from the LED through the optical system and on to the end user. Tis process is known as ray tracing (Figure 1), and demands a strong grasp of optical physics, material behaviour and manufacturing realities. Our team at Forge use convergence tools to refine designs, typically exploring multiple optic geometries during the day, then running overnight ray tracing simulations to determine the optimal solution. While simulation takes care of much of the optic design


Figure 2: A shelf full of prototype LED optics tools at Forge Europa


address this, it’s common to use separate optical systems positioned in front of the LED to collect, shape and direct the light – known as ‘secondary optics’. LED secondary optics can take many forms – lenses, reflectors,


fibres, light guides, diffractors, prisms – and oſten combinations of these. While there are plenty of high-quality OTS LED secondary optics


available, they all share the same limitation – being constrained in one way or another, either beam shaping, physical dimensions, optical efficiency, or even cost. Customisation, then, offers a clear path to overcoming these limitations and unlocking unique value in your LED-based product.


Approach to LED optic design Tere is a common perception that custom optical components are prohibitively expensive; that the design time, tooling costs and minimum order quantities make them unviable unless produced at vast quantities. Tis may have been true in the past, but, today, with companies


like Forge providing custom LED services, the cost is no longer a prohibitive factor. To design an LED secondary optics, the first and most important


rule is not to start with the optic. It’s essential to approach LED product design from a whole-product perspective, since the various design decisions are all tightly interconnected – and oſten competing. For example:


26 September 2025 www.electronicsworld.co.uk


process, we’ve found that, in almost all cases, prototyping is essential. Tat’s because real-world manufacturing processes – particularly plastic injection moulding – introduce uncertainties that simulation tools can’t always predict. Tings like light beam patterning or unwanted colour separation oſten only become apparent during physical testing. To address this, we’ve developed a rapid prototyping


capability focused on the most common type of LED optic – injection moulded plastic lenses. We’re able to cut small, single-cavity tools that can produce tens or even hundreds of prototype parts in as little as a couple of weeks; see Figure 2. Lenses like these can be manufactured from a range of


materials depending on the application, with the most common being optically clear polycarbonate (PC) and acrylic (PMMA). Glass and silicone can also be used where their specific mechanical or optical properties offer advantages. Reflectors, meanwhile, can be produced from metals such as aluminium or plastics with sputtered reflective coatings that can be tuned for specific optical filtering effects. Once prototype optics are ready, early-stage testing


can start alongside the LED, control electronics, thermal management, enclosure and other system elements. Tis allows rapid evaluation of the complete product with performance measurements, enabling the design to progress toward completion. Once satisfied with the prototype optics, the process can


move on to manufacturing the production tooling. For plastic lenses, this typically involves creating multi-cavity moulds with the necessary features for part removal and handling.


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