Custom Fly-Eye Glass Lenses
A fly-eye lens is a two-dimensional array of small lenslets used to divide and remix light. In an illumination system, the lenslets create multiple images of the source that overlap at a target or pupil plane, reducing hot spots and improving field uniformity.
China Lampoptics has disclosed production experience with stage-light fly-eye glass. The array is defined by lenslet geometry, pitch, active area and its position relative to the source, condenser and target plane.
Fly-Eye Optical Function
- Source division: each lenslet samples a portion of the incoming beam
- Angular redistribution: lenslet focal power redirects each sampled portion
- Field overlap: a second array or condenser overlaps the sub-images
- Homogenized output: the target plane receives a more uniform illuminated field
Array Configurations
| Configuration | System role | Typical use |
|---|---|---|
| Single fly-eye array | Redistributes a source where the downstream optics complete the mixing | Compact lighting systems |
| Matched array pair | Controls both sampling and angular overlap | Projection and stage illumination |
| Rectangular lenslet grid | Matches square or rectangular illuminated fields | Projectors and stage fixtures |
| Circular array | Fits a round optical barrel or beam | Spotlights and instruments |
| Cylindrical fly-eye array | Homogenizes mainly in one axis | Line and slit illumination |
Fly-Eye Lens Specifications
| Source size and divergence | ____ |
|---|---|
| Lenslet aperture | ____ mm |
| Pitch X / Y | ____ / ____ mm |
| Lenslet sag / profile | ____ |
| Lenslet focal length | ____ mm |
| Active area | ____ mm |
| Substrate thickness | ____ mm |
| Array-to-array spacing | ____ mm |
| Target plane and field size | ____ |
| Uniformity metric and limit | ____ |
Uniformity must be measured at the specified plane and field size. A photograph taken at an arbitrary distance cannot replace a defined spatial-uniformity measurement.
Molding and Alignment Control
Lampoptics' optical-lens and mold workshops can develop array tooling from the optical prescription and mechanical drawing. Molding must control every local lenslet while maintaining global pitch, array form and the mounting datum.
Available lenslet size, pitch, focal tolerance, array envelope and uniformity test equipment are ____.
Fly-Eye Glass Lens Processing
Lenslet Pattern Design
Lenslet pitch, curvature, orientation and array pairing are defined around the required homogenization performance.
Array Tooling
The repeated fly-eye structure is transferred into tooling while maintaining registration across the active area.
Precision Molding
The full array is molded in glass with controlled lenslet fill, wall distribution and annealing.
Uniformity Inspection
The lenslet pattern, alignment and illuminated field uniformity are checked with the intended optical arrangement.
Applications
- Stage and entertainment lighting: homogenized beams and color mixing
- Projection systems: uniform illumination of a spatial light modulator or image plane
- Laser and LED illumination: reduction of source structure at a defined target
- Inspection and machine vision: uniform fields for repeatable imaging
- Optical instruments: beam integration and pupil shaping
Fly-Eye Glass Lens FAQs
Is a fly-eye lens the same as any lens array?
A fly-eye lens is a lens array specifically used to divide and homogenize an illumination field.
Does the system need two arrays?
Many homogenizers use a matched pair, but some systems combine one array with other condenser optics. The configuration is defined by the optical design.
Which dimensions affect uniformity?
Lenslet pitch, aperture, focal length, array spacing, source size and target distance all affect the result.
Can Lampoptics make custom fly-eye arrays?
Lampoptics has relevant stage-light glass experience. The available custom pitch, lenslet and array range is ____.
How should uniformity be approved?
Define the source, drive condition, target plane, field size, sampling grid and numerical uniformity limit.
