Development of cost-efficient micro-optics for headlight systems: different loops of optimization leading to a glare-free and high range module

We introduce the development process of a new headlight module with perfect colour mixing and sharp upper edge for use as an additional module. Light is nearly collimated (<0.5° cone angle) for a variety of high-power automotive LEDs illuminating up to 1000 m street in front of the car. Key to success is an optimization process not only of the optical elements but also the materials and parameters of the injection molding process. A feedback loop of geometry measurement and simulation of real geometries does lead to acceptable tolerance values and geometry deviations. Finally, the optics in the module needs to be optimized with respect to mechanical tolerances and the inevitable fabrication errors. In this case it resulted in an additional element to be added at the entrance and exit surface of the initially designed optical structure. All steps were accompanied or carried out by simulations with LucidShape and FRED.