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Design method for C2-continuous tiled freeform lens arrays
Optics Letters
|February 27, 2026
Summary
This study introduces a novel design for smooth, continuous freeform lens arrays. The method uses saddle-shaped lenses to minimize stray light and improve manufacturability for illumination applications.
Area of Science:
- Optical Engineering
- Surface Design
- Illumination Optics
Background:
- Conventional freeform lens arrays often have discontinuities between tiles.
- These discontinuities lead to infinite curvatures, causing manufacturing challenges and stray light.
Purpose of the Study:
- To present a design method for creating second-order smooth (C2-continuous) freeform lens arrays.
- To enable seamless tiling of lens elements for globally smooth arrays.
- To minimize glare and stray light in illumination applications.
Main Methods:
- Developed a design algorithm for individual lens tiles.
- Incorporated saddle-shaped lenses between convex and concave elements.
- Ensured C2-continuity for seamless array formation.
Main Results:
- Achieved C2-continuous freeform lens surfaces.
- Demonstrated seamless tiling of lens tiles.
- Maintained control over the target irradiance pattern.
- Minimized glare and stray light effectively.
Conclusions:
- The proposed design method allows for the creation of C2-continuous freeform lens arrays.
- Saddle-shaped lenses are key to achieving surface continuity and minimizing optical aberrations.
- The method offers improved manufacturability and reduced stray light for illumination systems.
