Custom Glass Lens Arrays
A glass lens array places multiple optical elements on one molded substrate. The array fixes lenslet spacing and orientation, reduces the number of parts in the assembly and maintains optical registration under vibration or handling.
Arrays may be linear, rectangular, square, circular, hexagonal or application-specific. Each lenslet can be spherical, cylindrical, aspheric, concave or freeform depending on whether the array collects, distributes, images or homogenizes light.
Array Layouts
| Layout | Main characteristic | Typical use |
|---|---|---|
| 1D linear array | Lenslets repeated along one axis | Line lighting, scanning and elongated sources |
| 2D rectangular array | Rows and columns on controlled X/Y pitch | LED boards, stage lights and illumination |
| Circular or radial array | Lenslets arranged around an optical center | Round luminaires and instrument optics |
| Hexagonal array | Dense packing with sixfold neighborhood | Homogenizers and high-fill-factor fields |
| Mixed-function array | Different lenslets or zones on one substrate | Application-specific beam distributions |
Lenslet and Array Specifications
| Lenslet aperture | ____ |
|---|---|
| Lenslet radius / asphere | ____ |
| Lenslet sag | ____ mm |
| Lenslet focal length | ____ mm |
| Pitch X / Y | ____ / ____ mm |
| Pitch tolerance / cumulative error | ____ |
| Active area | ____ mm |
| Substrate size and thickness | ____ mm |
| Array flatness / form | ____ |
| Clear aperture and edge exclusion | ____ |
Pitch and registration are system dimensions. The optical origin, row direction and mechanical datum must be identified so the array aligns with the LED board, second array or downstream optics.
Registration and Mounting
- Datum edges: locate the array in X, Y and rotation
- Mounting holes or seats: reference the optic to the luminaire or optical bench
- Fiducials: support camera measurement and array-to-source alignment
- Orientation mark: prevents a rectangular or mixed-function array from being installed backwards
- Thermal clearance: allows the holder and glass to move without stressing the substrate
Array Molding Capabilities
Lampoptics has disclosed production experience with stage-light fly-eye glass and maintains separate optical-lens and mold workshops. Precision tooling controls the local lenslet surfaces together with global pitch and mechanical features.
Available lenslet size, minimum pitch, array envelope, glass grade and inspection equipment are ____. Coating may be applied where the array geometry and required performance permit.
Glass Lens Array Processing
Array Layout Review
Lenslet pitch, count, array outline, source map and mechanical datum scheme are confirmed.
Multi-Cavity Optical Tooling
The complete lenslet pattern is produced in one tool with controlled pitch and registration.
Array Molding and Annealing
The array is molded as a single glass component and cooled to limit warpage across the full footprint.
Registration and Beam Inspection
Lenslet geometry, overall flatness, mounting position and combined light distribution are evaluated.
Applications
- Stage lighting: fly-eye and multi-lens arrays for beam mixing
- LED luminaires: registered arrays over repeated LED layouts
- Projection and illumination: multi-channel collection and field shaping
- Sensors and imaging: repeated focusing or sampling elements
- Automotive and signal lighting: compact repeated optical functions
Glass Lens Array FAQs
What is the difference between a lens array and separate lenses?
An array fixes multiple lenslets on one substrate, reducing assembly parts and controlling relative pitch and orientation.
Can each lenslet have a different shape?
A mixed-function array is possible when the prescription, tooling and inspection method support the required local surfaces.
How is pitch specified?
Define X and Y pitch, origin, row direction, local tolerance and allowable cumulative error across the active area.
Can Lampoptics make fly-eye arrays?
Lampoptics has disclosed experience producing stage-light fly-eye glass. The available array and lenslet range is ____.
How is an array functionally tested?
Testing may measure focal position, beam distribution or field uniformity depending on the array's intended function.
