Project Description

Printed Linear Tilt Lens increases Project Customization for Paviom LoFoot Outdoor In-Ground Spot

Binary Lighting, a UK based project lighting company, works with independent designers and leading lighting brands to create a portfolio of professional, sustainable lighting luminaires. Among them is the Award Winning Paviom LoFoot spot for in-ground mounting in outdoor projects, one of their flagship products.

Paviom LoFoot In-Ground Spot

The modular Paviom exterior lighting range was designed by eco designer Jason Thawley, a former audio industry engineer who switched his career to the lighting field. The ‘LoFoot’ – its name is derived from ‘Low Carbon Footprint’ – includes a range of designer lighting products that are made by environmentally friendly manufacturing processes. The series greatly combine with efficient light sources and come with highly efficient optical components and control gear.

The Problem

Originally, the light scheme of the LoFoot in-ground spot includes a symmetrical light distribution angle. The integrated reflector unit – an interchangeable AR111 LED light source – is excellent for the upward illumination of an object, such as trees or signs, but less helpful for application as directed side light. The need for an easy-to-integrate interchangeable lens item that would adjust the beam angle was born. Unfortunately, as only low quantities of lenses were needed for customization of an average project, investment in tooling and inventory was not an option for the Paviom design team.

The Challenge

Paviom reached out to Luximprint with the question to create an asymmetrical tilt lens system. Intentionally, the lens should enable easy project customization and iterating of the symmetrical light beam into an asymmetrical one by simply laying in a secondary lens.

The Solution

The solution turned out to be simply: a tilt lens was created as an easy ‘add-on’ to the existing reflector optic system. A 20 degree tilt lens was created with a linear prism lens structure. The individual prisms of the lens redirect the primary lumen flow from the AR111 LED light source. After 3D printing the secondary lens, it was contour-cut by laser into the exact round shape to enable a perfect mounting and seamless fit into the LoFoot fixture.

“Paviom LoFoot lighting fixture easily customizable thanks to the 3D printed prismatic tilt lens that redirects the light from a standard symmetrical into a tailored asymmetrical light beam

Now, with an interchangeable 3D printed prism lens array, project customization is much easier than before. Lenses can be ordered to demand in exact quantities when they are needed!

Unique Project Features

  • No Upfront Investments: Thanks to the zero need for tooling, no working capital was needed or valued project/engineering time was lost;
  • Easy Iterations: Easy adjustment of symmetrical beam functionality into a tailored asymmetrical solution ranging from 1 to 44 degrees; several options were tested, finally the best solution was chosen for application;
  • Ordering on Demand: No minimum order quantities required and, resulting from that, no stock keeping. Project based ordering in exact quantities in a matter of days;
  • Exact Part Replication: After testing, validation and approval of the prototype, various small series were delivered over time to meet the need of every single project.

About Binary Lighting Ltd.

Binary Lighting Ltd. is a progressive lighting distributor, manufacturer and lighting design company based in the UK. Binary offers its clients a broad range of unique quality brands, design support and lighting solutions that suit a wide range of projects and requirements. Binary works closely with the designers of commercial interiors and exteriors, retail outfits, as well as luxury residential projects. They are able to facilitate the full process incl. design, supply and installation for their customers.

In their projects, they frequently apply the Award Winning “LoFoot” lighting Fixture from Paviom, a superb in-ground range of outdoor luminaires. From an in-ground position, the product is used for illumination of building facades, statues, forestry environments and any outdoor object that may need a powerful or more subtle illumination.

Project Suggestion:

If needed, an integrated color lens filter can be added to the lens array to color wash the objects to be illuminated, straight from one and the same manufacturing process!

Picture of 3D printed prism lens in clear and green color
Picture of green fresnel lens array - 3D printed onto frosted surface finish