Optics for Toy ManufacturerOptics for Toy Manufacturer

Derek Louie

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Optical ToysOptical Toys

• Imaging Systems• Projector, video player, binoculars,

camera, magnifier, microscopes, illusion, …• Illumination Systems

• LCD backlight, headlamp, flashlight, watch, …

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Optical ComponentsOptical Components

• Light Source• LED• Light Bulb

• Secondary Optics• Reflector• Optical Lens• Fresnel Lens• Collimator Lens

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CAE Optical DesignCAE Optical Design

• Advantages• Provides virtual prototyping, simulation

and optimization• Improve productivity, make your

products faster to market• Large reduction in development time

• CAE Design Software• Imaging – ZEMAX, CODE V,

CyberRay, …• Illumination – LightTools, ASAP,

Opticalc, OSLO, …

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Design ProcessDesign Process

1. Problem Definition

2. Pre-design

3. Initial Analysis4. Optimization

5. Final Analysis

• How good is the system?• Define the optical performance• Tradeoffs between requirements

• Decide no. of elements• Define the overall size• Choosing suitable optics

• Preliminary analysis• Selecting variables for optimization

• Alter the variables• Minimize the error functions

• Analysis of simulation results• Checking the specifications

6. Fabrication & Testing

• Fabrication of prototype• Performance inspection

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Case Study 1 Case Study 1 -- ProjectionProjection

• A low-cost projection system using plastic lenses

• Optical system consists of several aspherical lenses

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Case Study 2 Case Study 2 –– Mirage MirrorMirage Mirror

• Two parabolic mirrors with identical shapes

• The focal point of one lies just at the vertex of the other when they are placed on top of one another

Object

Image

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Case Study 3 Case Study 3 -- MagnifierMagnifier

• Use of Fresnel lens in order to reduce thickness

• Design with minimized image distortion

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Case Study 4 Case Study 4 –– HeadlampHeadlamp

Diode Encapsule

Anode

Cathode

Source Modeling

Simulation Results

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Case Study 5 Case Study 5 –– LCD BacklightLCD Backlight

• Aim at obtaining higher uniformity and luminous output

• Use of LEDs as light sources

• Lightguide with micro-lenses helps in light propagation