Creating a functional lens for F-Sign's "One LED" Series

Summary of the project

F-Sign might not be the largest OEM manufacturer of lighting fixtures, but they have a great vision for the use of materials to create something unique. A great example is their most prominent “One LED” series. Very likely to be the thinnest lighting fixture, with only 4mm thickness.

The first two LED fixtures they designed were a table lamp and a floor lamp version.
These  LED fixtures are great in design, but the light was spread too wide, and therefore not very functional. The second thing that was important is that the 120 degree beam caused a lot of glare (blinding effect of bright LED’s).

The Challenge

Design a lens that fits into our lighting fixture and turns the normal 120° beam angle into a 60° beam angle, to better illuminate the work area of the desk. In the same process the lens should also reduce glare. The lens was to be developed by another company, but they indicated they could not deliver within the time remaining. They had about two months. Now there were only two weeks left.

The limitations set by the lighting fixture (and the customer)

  • The LED fixture has a 6x6 LED Array, so the lens must also be in an array of 6x6
  • The room between the LED’s and the cover is 0,5mm
  • The beam spread needs to change from 120° to 60°
  • The lens must reduce glare caused by the high power LED’s
  • The lenses must be ready within two weeks, before the Light and Building trade show

Project approach

The custom 6x6 lens array, on just a 500 micron thin film, were designed and printed in one week and shipped to the F-Sign office in Germany. The design was approved and more pieces were printed and shipped in the second week. Just in time for the tradeshow. F-Sign was able to show a glare free, 60° beam angle when it counted, at the most important lighting tradeshow in Europe.

After the successful launch of the table lamp, and floor lamp they introduced a large range of fixtures from the same “One LED” concept, including wall lights, chandeliers, down lights and suspended luminaires.

Why was the project so successful?

  • The original supplier had problems making the optics, because of the thin substrate.
  • Timelines were critical
  • Both optics design and optics manufacturing were done by us
  • No tooling costs were involved
  • No large amount of optics had to be ordered, order on demand
  • The customer could really showcase their fully functional products
  • Very short delivery times

Without the speed of Luxexcel's fast printing process for LED optics we would never have managed to get our show presentation ready in time.

Simon French, Managing Director

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