Manufacturing

Polymer Optics Limited, founded in 1998 with our automotive subsidiary formed in 2014, are “engineers with light”.

If you’re looking for bespoke optic solutions for your project, please contact our experts to discuss your project in detail.

However, we do have a standard range of both holders and optics to suit a range of standard LED and typical applications.

Also in our range is a 7-cell cluster that has been used in a range of products with the different optical outputs from MR16 spot lights bot single colour and RGBW mixing though to high power large bundle fibre illumination, and we offer this in a number of materials for light throughput and heat including a silicone version.

Polymer Optics Limited, founded in 1998 with our automotive subsidiary formed in 2014, are “engineers with light”.

Polymer Optics Limited (POL). An innovative, exceptionally talented team who love nothing more than the challenge of engineering a bespoke solution for your lighting problem.

POL uses the latest computer optical design software for advanced 3D “unconstrained” optical raytracing, photometric analysis and imaging systems design.

This range of powerful commercial software is further enhanced by our own in-house developed design programs, which give POL specialist capabilities for novel types of optical applications.

These advanced optical ray tracing and photometric mapping routines give real-world simulation results of the optical system to demonstrate the design performance, and in many cases, remove the need for prototyping before moving to production tooling.

The most cost-effective optical designs integrate mechanical features into the optical components to aid assembly and reduce the number of components in the overall assembly.

The POL design team has wide expertise in integrated opto-mechanical design methods, including Design for Manufacture (DFM) and Design for Assembly (DFA) techniques.

In many cases, our opto-mechanical design input has to harmonise with the customer’s overall product aesthetics and the optical components become an important part of the final product styling.

Our optical design programs work directly with our CAD packages and provide a reliable communication to our customers, toolmakers and moulding facilities. Moldflow analyses are also used to determine product and process capability prior to tooling builds.

Manufacturing

Through a proven network of partner precision toolmakers, the construction of optical mould tools is carried out under POL’s tool design and close project management.

In many cases, our specialist toolmakers are skilled in optical surface generation and polishing, so can produce the entire tool set for the product to POL’s specification. However, POL’s extensive partner network of precision machining centres of excellence, enables us to have critical parts of the tool made by different processes and in different geographic locations where necessary, to bring together the best technology mix into the final tooling package.

This enables us to design, tool and manufacture novel product applications, selecting the best, most suitable technologies available.

The Flat Ceiling Lens is designed for passive infra-red (PIR) sensors where aesthetic appearance is a key consideration.

Using free-form Fresnel facets, the lens maintains image quality while delivering wide-area coverage — a single sensor can typically monitor a 10 × 10 m room.

Its near-square detection pattern ensures coverage into room corners and reliable close-range (small movement) detection. The flat form, combined with the relatively short focal length, allows designers to create low-profile sensor products without compromising performance.

Samples will be available on the stand.

The Flat Ceiling lens is designed for passive infra-red (PIR) sensors where product aesthetic appearance is an important consideration. The lens uses free-form Fresnel facets to maintain image quality and ensure a wide coverage area. One sensor can typically cover an entire 10 x 10m (33 x 33ft) room.

The lens has a near square zone pattern ensuring that detection is possible into the corners of the

room, while still giving good close-up [small movement] detection. The flat nature of

the lens, combined with the relatively short focal distance, allows the designer to consider a

low-profile sensor product.

Simple and quick to use PIR lens that can be integrated into your product

Features

• Designed to press onto standard T05 pyro Horizontal curtain and circular beam patterns
• Choice of profile shape to suit product styling
• Designed using optical ray-tracing software
• Compact shape with clearance for components
• Available in natural, white and black colours

APPLICATIONS

• Office and household lighting control
• Motion detection for security applications
• Individual luminaire switching
• Fan and air conditioning control
• Control panel illumination for appliances
• Vending machines, ATM’s, streetlights

Polymer Optics Limited, founded in 1998 with our automotive subsidiary formed in 2014, are “engineers with light”.

POL designers have been at the forefront of PIR lens design for over 25 years. Our in-house developed ray-trace software can accurately predict the performance of the PIR lens before committing to tooling.

We also develop novel manufacturing methods for precision tooling manufacture that these lenses demand and high-quality moulded lenses.

We have a range of standard quick and simple to use lenses

Also our design team have been designing for the major maunfuactures for many years hence many of the PIR lenses on display around the show will have had our input in.

We are able to design to meet your technical lighting needs with due surface freeform lenses.

our standard range of these FreeForm lenses are based around the needs for EN54 part 23 and emergency lighting needs.

Polymer Optics Limited, founded in 1998 with our automotive subsidiary formed in 2014, are “engineers with light”.

POL has developed free form surface design and mould tool manufacturing techniques that allow the creation of optical surfaces, which can direct light from an LED source into non-circular or elliptical beams with a controlled distribution of light within those areas.

This technology allows luminaire manufacturers to significantly increase the efficiency and quality with which their products can illuminate wide areas compared with products based on TIR optics or reflectors.

Free-Form optics are most commonly found in street lighting, but since the first designs completed by POL in March 2010, they have been used in a wide range of applications, such as beacons and emergency lighting.

We will be showing our standard range of EN54 part 23 optics and large area optics that have been designed for square rooms and corridoors

POL combines world-class design expertise with advanced manufacturing know-how to deliver smarter lighting solutions.

Our optical design team goes further than standard practice, combining powerful commercial software with proprietary in-house tools to truly engineer with light.

This unique approach delivers exceptional illumination performance in demanding applicationsBy optimising Design for Manufacture (DFM) and Design for Assembly (DFA), we reduce component counts, accelerate assembly, and eliminate unnecessary tooling complexity leading to reducing costs.

Polymer Optics Limited, founded in 1998 with our automotive subsidiary formed in 2014, are “engineers with light”.

If you’re looking for bespoke optic solutions for your project, please contact our experts to discuss your project in detail.

However, we do have a standard range of both holders and optics to suit a range of standard LED and typical applications.

Also in our range is a 7-cell cluster that has been used in a range of products with the different optical outputs from MR16 spot lights bot single colour and RGBW mixing though to high power large bundle fibre illumination, and we offer this in a number of materials for light throughput and heat including a silicone version.

Polymer Optics Limited, founded in 1998 with our automotive subsidiary formed in 2014, are “engineers with light”.

Polymer Optics Limited (POL). An innovative, exceptionally talented team who love nothing more than the challenge of engineering a bespoke solution for your lighting problem.

POL uses the latest computer optical design software for advanced 3D “unconstrained” optical raytracing, photometric analysis and imaging systems design.

This range of powerful commercial software is further enhanced by our own in-house developed design programs, which give POL specialist capabilities for novel types of optical applications.

These advanced optical ray tracing and photometric mapping routines give real-world simulation results of the optical system to demonstrate the design performance, and in many cases, remove the need for prototyping before moving to production tooling.

The most cost-effective optical designs integrate mechanical features into the optical components to aid assembly and reduce the number of components in the overall assembly.

The POL design team has wide expertise in integrated opto-mechanical design methods, including Design for Manufacture (DFM) and Design for Assembly (DFA) techniques.

In many cases, our opto-mechanical design input has to harmonise with the customer’s overall product aesthetics and the optical components become an important part of the final product styling.

Our optical design programs work directly with our CAD packages and provide a reliable communication to our customers, toolmakers and moulding facilities. Moldflow analyses are also used to determine product and process capability prior to tooling builds.

Manufacturing

Through a proven network of partner precision toolmakers, the construction of optical mould tools is carried out under POL’s tool design and close project management.

In many cases, our specialist toolmakers are skilled in optical surface generation and polishing, so can produce the entire tool set for the product to POL’s specification. However, POL’s extensive partner network of precision machining centres of excellence, enables us to have critical parts of the tool made by different processes and in different geographic locations where necessary, to bring together the best technology mix into the final tooling package.

This enables us to design, tool and manufacture novel product applications, selecting the best, most suitable technologies available.

The Flat Ceiling Lens is designed for passive infra-red (PIR) sensors where aesthetic appearance is a key consideration.

Using free-form Fresnel facets, the lens maintains image quality while delivering wide-area coverage — a single sensor can typically monitor a 10 × 10 m room.

Its near-square detection pattern ensures coverage into room corners and reliable close-range (small movement) detection. The flat form, combined with the relatively short focal length, allows designers to create low-profile sensor products without compromising performance.

Samples will be available on the stand.