Characterization of freeform optics in automotive lighting systems using an Optical–Geometrical Feature Based Method

The use of freeform optics has been more widespread. It is difficult to evaluate the optical performance of the freeform optics due to its geometrical complexity. This paper presents a novel method named Optical–Geometrical Feature Based Method (OGFM) for the characterization of freeform optics. The method attempts to establish the relationship between the geometrical features of freeform surfaces (e.g. the surface roughness and form error) and their corresponding optical performance. Hence, the optical performance of the freeform optics can be evaluated by the measurement of the geometrical features which is relative easy to be carried out as compared to the optical performance tests conducted in automotive lighting systems. A series of simulation experiments have been conducted on the freeform optics in an automotive lighting system. The results show that the geometrical errors in micrometer scale appear not to have significant effect on the optical performance of the freeform optics. However, the optical performance is adversely affected when the geometrical form error increases from more than tens of micrometers scale to sub-millimeters scale. The successful development of the proposed OGFM provides an important means for the optimization of manufacturing tolerance, the selection of appropriate optics manufacturing process, and the evaluation of the optical performance evaluation of the freeform optics.