Functional integration for additively manufactured reflectors

The demand for custom designed optical components, e.g. reflectors with specific light distributions have risen heavily in recent years in several industrial sectors. In order to manufacture such individualized reflectors, additive manufacturing is becoming increasingly important due to the large number of design options available. In addition to the possibility of realizing free-form optics, additive manufacturing offers the potential for functional integration and optimization. In this work, the approach to functional integration of additively manufactured reflectors is investigated by seeking additional functions such as cooling fins, cable guides and fiber optic connections or component reduction. A method is presented, with which a broad range of technical functions can be identified that are suitable for functional integration. Following optical, mechanical, thermal and electrical concepts are derived. Using a bicycle lamp demonstrator, which is manufactured using SLM and FDM processes, selected concepts for hybrid manufacturing and functional integration are examined. In addition, design guidelines for the integrated functions are presented.