Creating a low glare downlight luminaire for O/M

Summary of the project

O/M has developed a new and very high quality product range, based on some of Bartenbach’ s human centric design concepts. All these new products have very high quality white light, and very low glare ratios making these lamps extreme well suited to use in high quality working environments, where people want to have a pleasant working environment.
By using a highly facetted micro-reflector concept for their downlight O/M realized all of the above in their product “One”. “One” is a ceiling recessed luminaire with extremely precise beam angles, for general and accent lighting. This innovative range of downlights achieves perfect glare control and an excellent cut-off. Besides this great functional concept they also achieved a very nice looking fixture.
Their product “One” is not the only product O/M developed and launched during the last Light + Building show in 2016. They also released a few other great new fixtures with the same high quality white light and low glare values in their new 2016 product range.

The challenge

The challenge was to create a product which had an excellent cut-off, superb glare control and minimum difference between the beam angle and the field angle.

Problem definition

The lighting industry’s standard defines that the beam angle is the angle between those points of either side of the beam axis where luminous intensity is approximately 50% of its maximum. The field angle ends when the luminous intensity reaches 10% of its maximum.
“One” concentrates in its beam angle of 90% of the maximum luminous intensity. As a result, the difference between the beam angle and the field angle is practically nonexistent. Creating a sublime cut-off. There is excellent glare control and no light spill.

The solution

The Lightcore, center of the “One”, is built based on micro surfaces with complex geometry coated aluminum alloy. This creates a high-gloss, entirely mirrored surface. This resulted in an accurate reflector which could define and control the light beam, achieving maximum efficiency.
The Printoptical © Technology of Luxexcel was a great fit for creating the prototype of the reflector for the “One”.
Our fast service where we printed the part in just 5 business days before we had it coated made sure that they did not lose any time in the developments stages, and Bartenbach and O/M could quickly evaluate both the visual appearance of their concept, measure the emitted light, and compare it to the simulation. With a near perfect match as a result.
Due to the high complexity of the faceted reflector our unparalleled design freedom offered a great benefit, because in 3D printing complexity is no issue.
The first design was changed after the evaluation of our first prototype, as they thought the light output and the visual appearance was not as they expected. This resulted in a design change and quickly we printed the iteration, with almost no loss in time or money, since no mold was made yet.
Due to the Luxexcel service O/M and Bartenbach were able to prototype the design for the “One” with great success. They finalized the fixture and launched “One”, together with the rest of their new products at Light and Building 2016 where the response from the crowds were even beyond their expectations.

Unique project features

  • Fast delivery: After our short lead time of only 5 business days for printing, they were shipped of for coating. O/M received the custom reflector parts within two weeks rather than 6-8 weeks or even months. Enabling them to quickly build the demonstrator to evaluate both the visual appearance and the light output/photometric data.
  • Design freedom: Due to the complex nature of the highly facetted part, other prototyping methods would have been very expensive and time consuming.
  • Iterative design processing: The first design was printed and tested. After the visual and photometric evaluation the design was adjusted and a second design was also quickly printed.
  • No upfront investments: Without the need for tooling, no working capital was lost to molds or tooling parts. Especially since the first design was discarded that was a great benefit.

A good product simulation, or prototype is more and more important in product development. It makes it possible to reduce loops and in consequence also reduces development process lead time.

Paula Osório, R&D & Production Manager at O/M

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