Feature: LEDs


More than just performance While the principal benefit of custom LED optics is the optimised performance, there are oſten many additional ways in which customisation can add value. For example, it is quite common to integrate mechanical features directly into the optic itself, allowing it to interface seamlessly with the product enclosure. Tis can include adding seals or mounting features and alignment aids, which are particularly useful in exterior and ruggedised applications such as automotive lighting, explosion- proof fixtures, street lighting and marine environments. Another subtle but highly-effective customisation is the creation of LED optic arrays. Tese can reduce manufacturing


and assembly costs whilst ensuring precise inter-optic alignment. Arrays are especially valuable in high-output or directional lighting applications like stage and theatre lighting, searchlights and urban streetlighting.Tey’re also widely used in non-human vision systems – for example, in ultraviolet curing (used for printing, adhesive bonding and stereolithography), as well as infrared illumination for machine vision inspection, night vision in security systems, automatic number plate recognition, and even cosmetic or therapeutic applications such as skin treatment. So, whatever your LED application, do consider the many


benefits of LED optic customisation – particularly when optics are designed as a fully integrated part of your overall product.


LED OPTIC CUSTOMISATION – EXAMPLES Here are just a few of the many innovative applications Forge had been working on over the years:


Borosilicate glass lens manufactured in open mould with edges ground and polished Helicopter landing deck pixel in green or amber, part of a highly-efficient LED helideck system for offshore use. It meets CAA CAP437 standards for helideck lighting. Operates in temperatures of ±50o


landing pressure, aviation fuel spillage and marine environment. Prototype array of high-power ultra-narrow LED collimators


High-reliability high-performance LED searchlight with illumination distances of several kilometres.


It provides high optical performance, and very high reliability, including LED redundancy and full solid-state professional security grade searchlight for visible and IR target illumination.


Full multi-optic optical system solution comprising plastic primary lens and aluminium diffused reflector Class-leading high-power commercial downlight.


It provides class-leading system efficiency, low glare, ‘squared’ illumination. It is protected by Forge patents in the UK, the US, and Germany.


Six-part collimator array for use with blue/violet LEDs Huge-array LCD-screen-type stereolithography 3D print resin curing.


Its high collimation efficiency enables low 3D-print pixel size due to reduced inter-pixel crosstalk. Its 6x array provides economy of system manufacture due to ease of assembly.


Small optic from 8x cavity production tool shown on sprue Architectural wall-wash illumination.


Very small size, high-quality wall-wash beam with system in very close proximity to wall giving excellent illumination aesthetics (beam colour purity).


15-LED combination optic array providing precision light distribution and full ingress and impact protection Street and highway lighting.


It offers class-leading system efficiency and meets the diverse requirements of both street and highway lighting standards in a single modular light engine. It has fully integrated ingress and impact protection.


Single LED ultra-wide light dispersion lens Illumination of road bollards.


Its extremely high system efficiency is achieved in combination with low-cost high-reliability passive control electronics. The optic also incorporates ingress protection.


Ultra-narrow beam optic for single high-power LED For high-end architectural downlights.


www.electronicsworld.co.uk September 2025 27


C. Extremely tough, withstanding helicopter


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