Exploring 3D Printed Large Format Optics For Rapid Validation and Demonstration Purposes

The additive Luximprint Printoptical Fabrication process finds its origins in large-format digital printing. While the process has significantly developed and mutated over time to custom build specifications, some of the inherent large format possibilities remain to this day. The build tray of the Printoptical Process remains rather large, compared to typical 3D print equipment available on the market, and the flexibility in scaling beyond the established boundaries is still present. Whether it’s large format lighting, display lighting or other super-sized embossed or textured optical surfaces, the process is a key enabler in rapid prototyping of functional proof of concepts, one-offs, prototypes and pre-series volumes for large optical parts.

3D Printed Custom Optics – Both Large and Small

The typical outer dimensions of the build tray in the Luximprint Printoptical Process are established at 650*650 mm quadra, and can be extended to demand. Whether the full build tray is occupied with small lenses, or one rather large lens,  doesn’t really make a difference in the processing. Likewise, it doesn’t matter whether all parts are the same, or have a (slightly) different appearance (“mass-customization”). As long as the average ‘lens type’ is the same, and the same print settings can be applied, interesting combinations can be realized.

Complexity, as such, is less of an issue what makes ‘Prototype Variations’ (multiple master items in one job, almost the same, slightly different in design) and ‘Prototype Iterations‘ (next job, with likewise approaches) an interesting option utilizing the Printoptical Process. It allows the user to trial-and-error multiple designs at the same time, choose the best option, and move forward from there. In case the printed part is not performing as expected (for whatever design/manufacturing reason), a next iteration can be implemented at speed.

Logically, from a commercial perspective, build-tray occupation does matter, as the cost for the job can be amortized over just one, a few, or multiple items. In any case, the optical 3D printing process remains a fast, flexible and cost-effective manner of having custom optics prototyped rapidly.

Planar and Dual-Sided Lens Application

Thanks to the use of a ‘substrate’ – a planar thin film or optical sheet material that holds the additively generated optical features –  large surfaces can be foreseen with precise optical features at both sides of the plane. These features can be identical, but also totally different in design. Also, external parts can be loaded into the process, be it past development or external ‘off-the-shelf items’, and be reworked with added optical elements, optical textures, or Frosted Finishes. In that light, we wrote a blog post a while ago about ‘Printing on External Sheets and Lenses‘, which you may find interesting too.

Example of a 3D printed optical prism structure applied on two sides of a given substrate (Image courtesy of Luximprint).

Flexible Optical Substrates

The use of flexible sheet materials enables the optical sheets to be deformed/folded in its application, at least as long as the added optical textures are not too ‘heavy’ connected. Light textures, even when connected, can still be folded, once a given lens structure becomes too ‘solid’, it may just crack or, worst case, delaminate from the substrate. Freestanding lens items are typically not a challenge.

Large Format Optics at DDW24

At the 2024 edition of Dutch Design Week, Helder Design Studio is showcasing its latest lighting installation named ‘SCHERMLICHT‘. Driven by an engine of 2D LED Pixel Screens, the 3D printed large format optics complement the installation turning it into a 3D spatial experience. The project that seeks to redefine LED screens not merely as static displays but as spatial sources of light. Rather than confining the visual impact to a flat, two-dimensional plane, we envision these screens as integral components in creating three-dimensional light volumes. This approach allows light to extend beyond the boundaries of the digital domain, enhancing and interacting with the physical environment using tailored optics to control the lighting dynamics of a given space.

A snapshot of a larger optical lens plate with 3D printed micro-lenses applied (Image courtesy of Luximprint)

Printed Optics: Versatile and Fast