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Harold BruntOptomechanical Designer, Corporate Officer, VP LumenFlow Corp.Board Member, United Lumen, LLC
LumenFlow Corp. is a Photonics Engineering, Consulting and small manufacturing company located in Wyoming, Michigan. We offer an interdisciplinary approach to photonics problem solving specializing in:
Precision OpticsVisible, NIR & IR Lens AssembliesInstrument Grade LasersMachine Vision IlluminationLED Optics & Systems Engineering
LumenFlow Corp. sits on the Board for the MSSLA and MI-Light.
LumenFlow’s Patented360° View Lens
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Harold BruntOptomechanical Designer, Corporate Officer, VP LumenFlow Corp.Board Member, United Lumen, LLC
LumenFlow Corp. is a Photonics Engineering, Consulting and small manufacturing company located in Wyoming, Michigan. We offer an interdisciplinary approach to photonics problem solving specializing in:
Precision OpticsVisible, NIR & IR Lens AssembliesInstrument Grade LasersMachine Vision IlluminationLED Optics & Systems Engineering
LumenFlow Corp. sits on the Board for the MSSLA and MI-Light.
LumenFlow’s Patented360° View Lens
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For Optical Engineering, Ray Trace, and Lighting Simulation LumenFlow Corp. utilizes:
Zemax OpticStudio 16.5Zemax LensMechanix Add-In for SolidWorksOptisWorks 2016 Add-In for SolidWorks 2016 with:
ODESIS (Optical Design) packageSPEOS for SolidWorks 2017 Add-In with:
Photometry Package Colorimetry Analyzer Option Mass Fluorescent Materials Generator Option3D Texture OptionMulti-Threading 16 Threads Option
LumenFlow has been a licensed Zemax user since 2000, a SolidWorks user since 2002, and an OptisWorks user since 2005.
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www.lumenflow.com
A product does not need to be complex to benefit from the investment in simulation even after initial prototype. Simulation of the performance and making corrections in the design prior to making tooling commitments saves significant time and money.
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The “ClipCleany” Pet ProductSimulation after optimization
The “ClipCleany” Pet ProductAs it appeared on ABC News
www.lumenflow.com
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LumenFlow can optimize a simple consumer LED lighting design or take a complex laser based instrument from concept prototype to manufacturing.
Laser Based cylindrical object measurementSystem concept ray trace, casting print,
assembly & alignment
www.lumenflow.com
LumenFlow produces a series of VIS, NIR and IR lenses for instrumentation. The Lens elements and machined components are all sourced in the USA.
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LumenFlow VIS, NIR & IR Lenses for Instrumentation from ray trace, to
component sourcing to manufacturing
www.lumenflow.com
LumenFlow designed a unique Machine Vision Lens System which will allow a user to view a cylindrical surface as a flat image in one view with one camera. Optional optics create the flexibility of internal or external surface inspection with up to 40μm resolution.
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LumenFlow 360 External ViewLens System
The “Sample” as viewed on screen (left)Etching Detail analyzed by third party software
www.lumenflow.com
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LumenFlowand Dow Corning® Corporation Moldable Optical Silicones:
Our work with Dow Corning Corporation Moldable Optical Silicones started with the development
of our LED remote phosphor technology in 2012.
www.lumenflow.com
LumenFlow LED on Display in Dow Corning Corporation’s LightFair International 2013 Booth (Left), LumenFlow “Mini HEOC” Sample for 2014 Booth (Right)
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LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
LumenFlow has been a technical resource at LightFair International for Dow Corning Corporation from 2013 through 2016 and was a co-exhibitor in 2017.
www.lumenflow.com
LumenFlow Compound Optic Kiosk for Dow Corning Corporation’sLightFair International 2015 Booth
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LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
LumenFlow has characterized Dow Corning Moldable Optical Silicones to generate material and surface definition files for SPEOSsoftware: Materials such as MS-1002 and MS-4007, and surfaces for multiple cross-sections and specular and matte finishes of MS-2002.
LumenFlow designed the Wide Angle Reflector using Dow Corning MS-2002 moldable White Reflector Silicone.
www.lumenflow.com
Wide Angle Reflector Design, Molded Part, and output with LED source
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www.lumenflow.com
Design features:• Two lenses joined along the center by a light pipe.• Narrow angle output from the source along the center of the optic is shaped by a
single lens (two surfaces).• Wide angle output is shaped by two lenses (four surfaces).
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
LumenFlow designed the Compound Optic using ODESIS (Optical Design) package and SPEOS for SolidWorks 2017. The Compound Optic is molded using Dow Corning MS-1002 and is a replacement for a thermoplastic TIR in a machine vision application.
LumenFlow and Dow Corning Corporation Moldable Optical Silicones:
Predicting the performance of complex structures is made possible by creating those features in the CAD model. LumenFlow designed a Reflector Array for an Acorn Style Street Light using Dow Corning MS-2002 moldable White Reflector Silicone.
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The Brandon Industries, Inc.Acorn Street Light Product
www.lumenflow.com
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
Dow Corning Optical Silicone is capable of replicating very fine features. Small features are useful as diffusors for example but will severely tax CAD system resources. LumenFlow has been working with Dow Corning and Tenibac –Graphionto model, simulate and measure several available textures. Existing textures are measured and then modeled using the SPEOS for SolidWorks 2017 3D Texture Option.
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www.lumenflow.com
MaxIMDL Image of Tenibac – Graphion tif file (Left), Multiple profile cross sections (Right)
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
The profile cross sections exported from the image processing software are scaled using data from measurements made using a Keyence optical microscope system.
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www.lumenflow.com
Keyence Image of Tenibac – Graphion textured tool (Left), Molded Silicone part (Right)
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
The profile cross sections exported from the image processing software are scaled using data from measurements made using a Keyence optical microscope system.
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www.lumenflow.com
SPEOS for SolidWorks 2017 3D Texture (Left), SPEOS simulation output at 10mm (Right)
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LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
The goal for the demonstration textures is to provide lighting designers the opportunity to trial optical silicone and known existing textures in their designs. As files are verified and measured the textures will be made available as BSDF surface files.
The idea is to:Model an existing textureTest and verify the modelCreate a BSDF file for customers
Also providing the option so that:If a customer does not have the 3D Texture Option, LumenFlow will create a textureDow Corning will prototype, test and measureCreate a BSDF file for the customer
Watch this space for a white paper describing the process and for more moldable optical silicone
designs: http://www.dowcorning.com/content/etronics/etronicslanding/moldabledemokit.aspx
www.lumenflow.com
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www.lumenflow.com
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
The LumenFlow Under Cabinet Strip Light includes a design that minimizes the optic size while directing the light where needed. Traditional thermoplastic diffusors will often introduce a shift in color temperature as well as a significant loss in output. Injection moldable optical silicone from Dow Corning Corporation also allows the design to incorporate robust snap assembly and sealing features.
Tenibac-Graphion texture designed in SPEOS for SolidWorks (Left), Detail of Strip Light Optic (Center), Output pattern, measured for eight (8) LED single Optic section (Right)
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www.lumenflow.com
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
The desires for low glare and reduced hot spots are realized with a low-profile design that introduces no changes to the LED output such as color separation or change in color temperature.
SPEOS for SolidWorks 2017 Simulation (Left), Detail of Strip Light Glare (Right): LumenFlow Corp. Optic Design (Left), Diffusing Thermoplastic (Center), Clear Thermoplastic (Right).
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LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
Often there are applications for fixture designers creating low cost LED linear lighting where the challenge of putting light where it is needed is compounded with the requirement of directing the light away from where it is not wanted. Asymmetric undercut features and unique textures were utilized by LumenFlow Corp. in a design made possible using Dow Corning moldable optical silicone for a low-profile Wall Wash.
www.lumenflow.com
Tenibac-Graphion texture designed in SPEOS for SolidWorks (Left), Output pattern, measured for eight (8) LED single Optic section (Right)
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
Information such as product identification, branding, or ownership is often communicated using low cost LED illumination and projection. LumenFlow designed the Projector Optics using SPEOS for SolidWorks 2017. The Optics are molded using Dow Corning MS-1002 and the projector is an exterior automotive application.
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Basic User generated file (Left), Complete User generated file (Right)
www.lumenflow.com
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
To compare the simulation results and to assess the differences for material definitionsfor Dow Corning MS-1002 our projector was used consisting of a commercially available LED, and a grid pattern “film”.
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Image and Detail from: Basic User generated file (Left), Complete User generated file (Right)
www.lumenflow.com
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
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Projected Image from Prototype (Left), RGB Profile (Center), Monochromatic (Right)
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
How accurate is accurate enough?Does it really matter all that much?
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Basic User generated file (Left), Complete User generated file (Right)Normalized Cross Correlation (NCC) and Root Mean Square Error (RMS):
Basic User generated file: NCC = 86.2%, RMS = 12.1%Complete User generated file: NCC = 97.4%, RMS = 8.0%
www.lumenflow.com
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www.lumenflow.com
Material Definition
Refractive Index (Index Variation)
• The Index Variation data field is completed using the index of refraction as measured by Dow Corning using a Varian Cary 5000 UV-Vis-NIR spectrophotometer re-ordered from the provided 850nm – 300nm to 400nm – 700nm.
Absorption & Scattering Properties• To complete the Absorption Variation and Scattering Variation data fields, throughput
data at multiple wavelengths was used as the fixed points in a curve fitting algorithm togenerate the absorption and scatter coefficients from 400nm to 700nm.
• For each wavelength (λ), measure the output of a laser source at the input (T0) and in thefar field (T1) after exiting a sample material rod in multiple lengths (x).
• Calculate the transmission “T” for each wavelength for the rod samples. For each lengthand wavelength:
T = T1/T0.
• Calculate the extinction coefficient αT for each wavelength and sample, whereT1/T0 = T = exp(-αT · x), and αT = - ln(T)/x
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www.lumenflow.com
Absorption & Scattering Properties, continued
• Generate the extinction coefficient relation for the wavelengths between 400nm and700nm using a curve fit function, whereby the goodness of fit was maximized by theoptimization of NCC and RMS values for light intensity over the length of the samplerod. The extinction coefficient equals the sum of the absorption (α’) and scatter (μ)coefficients so that:
αT (λ) = α’(λ) + μ(λ) .
• The curve fit function approximates α’ using C1/λn1 and μ using C2/λn2 where C is aconstant and n is the exponent of the wavelength. Note that the scatter relation andphase angles will be a mix between Rayleigh and Mie, due to the complex nature ofthis material, therefore it is necessary to use a 1/ λn relation, where n1 = 1 and 2 ≤ n2 ≤4 and is determined by a best fit. The Henyey-Greenstein formula is selected over Miein the OptisWorks Scattering properties Tab in order to minimize simulation times.
• The curve fit variables are calculated for best fit for the formula:
(C1/λn1) + (C2/λn2)
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www.lumenflow.com
Absorption and Scattering Properties, continued
• Measurement data for scatter from the side surface of a 50mm rod, in addition to thenear and far field throughput data, was used to calculate the ratio between scatterand absorption. The extinction coefficient curve is multiplied by the calculated ratio togenerate the absorption (α’) and scatter (μ) coefficient curves.
• Selecting the “Henyey-Greenstein formula” option automatically populates the tablewith the Anisotropy Factor setting of .900.
Surface Definitions
Scatter & Reflectivity
• To populate the advanced scattering surface data field, the surface reflectivity from300nm to 800nm in 25nm increments are generated using a best fit curve Fresnelcalculator to generate the Real and imaginary components of the Reflection Coefficientreferencing the reflectivity for the given wavelength at 5° as measured by Dow Corningusing a Varian Cary 5000 UV-Vis-NIR spectrophotometer.
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www.lumenflow.com
Scatter & Reflectivity, continued
• The values for n and k are assigned as variables and are adjusted so that the difference squared between the measured reflectivity at 5° and the calculated reflectivity is minimized. The calculator is an excel spreadsheet using the formulas:
Rp = [((n2+k2)cosΘ2)-(2ncosΘ2+1)] / [((n2+k2)cosΘ2)+(2ncosΘ2+1)]2
Rs = [(n2+k2)-(2ncosΘ)+cosΘ2] / [(n2+k2)-(2ncosΘ)+cosΘ2]2
R = (Rp+ Rs)/2
Where:
Rp = Reflection Coefficient of p polarized light
Rs = Reflection Coefficient of s polarized light
R = Random Reflection Coefficient of the averaged Rp andRs values.
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www.lumenflow.com
The Normalized Cross Correlation (NCC) and the Root Mean Square (RMS) error
The NCC is calculated using the formula:
NCC = ∑[IΘsn - Īsn][IΘen - Īen] / √(∑[IΘsn - Īsn]2∑[IΘen - Īen]2)
Where: IΘsn is the simulated data and IΘen is the measured data, and Īsn is the simulated data and Īen is the measured data Mean value. The NCC% is considered acceptable when the value exceeds 99%.
The RMS error is calculated using the formula:
RMS = √((1/M) · ∑ (IΘen - IΘsn)2)
Where: M is the number of data points. The RMS% is considered acceptable when the value is less than 5%.
LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
When the desired image is a bright white projection the edge is usually separated into a “rainbow” which can cause an image to appear to be out of focus. LumenFlow Corp. is developing an all silicone design that reduces chromatic aberrations which are normally seen as color separation at the edge of the image.
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Detail of color separation, 0.01mm projected feature: Polycarbonate system (Top), all silicone Design (Bottom)
www.lumenflow.com
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LumenFlowand Dow Corning Corporation Moldable Optical Silicones:
LumenFlow continues to design demonstration optics and characterize materials for Dow Corning Corporation and Dow Corning Corporation continues to display and mold our proprietary designs for the benefit of their customers.
More moldable optical silicone designs:http://www.dowcorning.com/content/etronics/etronicslanding/moldabledemokit.aspx
www.lumenflow.com
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www.lumenflow.com
The software and what it enables us to accomplish continues to be a major part of our business for our own product development and the services we offer our clients. There are several simulation software packages on the market but it has been the exceptional technical support we have received over the years in addition to the software’s capabilities that insures that we will remain an Optis customer.
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THANK YOU!
3685 Hagen Drive SE
Suite B, Wyoming, MI 49548
www.lumenflow.com
269-795-9007