Compact LED Optical Stack Design

@LiveExperts

Hello, With a comprehensive expertise in CAD/CAM and Mechanical Engineering, I am well-acquainted with the intricacies and challenges of designing compact optical systems that consistently deliver high-output in demanding environments, making your project an ideal fit for my skills and experience. Moreover, having successfully executed numerous projects involving precision systems in medical applications, I’m well-aware of the significance of efficiency, reliability, and sticking to a stringent set of parameters. Incorporating my deep understanding of optical design and my proficiency with software including Zemax and LightTools, I will develop accurate ray-trace simulations that will successfully bring your envisioned stack to life while meeting the stringent mechanical constraints you’ve stipulated. Additionally, my familiarity with off-the-shelf parts sourcing where possible will considerably streamline the execution process while keeping the project within budget. Choosing me means opting for meticulous attention-to-detail and unwavering commitment to project success. I am excited to leverage my skills to propel your project forward and deliver an optical sequence that not only meets but exceeds your expectations. Let's transform your detailed requirements into an innovative reality! Thanks!

@geno700

Hi, I’m Ahmed. I am a Mechatronics Engineer with 6+ years of specialized experience in Fusion 360 and integrated hardware development. I don't just provide digital designs; I operate a fully equipped R&D lab with 3D printing, CNC, and precision craft tools. This allows me to virtually design and physically validate your prototype, ensuring it works in the real world before you move to mass production. My expertise includes: Mechanical: Complex CAD/CAM for 3D printing and CNC. Electrical: Custom PCB design and sensor integration. Software: Embedded C and firmware for smart devices. I’d love to hop on a 10-minute chat to discuss your technical requirements and how I can help bring this product to life. Best regards, Ahmed

@kkirandeep582

Drawing on my extensive experience in mechanical design and engineering, I am ready to step up to the challenge of developing your Compact LED Optical Stack. Having worked on various precision systems in the past, I am acutely aware of the demands that high-output optical assemblies face in medical and industrial environments. This understanding allows me to foresee potential issues and integrate early countermeasures, ensuring a design that is not only efficient but also exceptionally reliable. In addition to my mechanical expertise, I’m a versatile freelancer proficient in many software applications within 3D and 2D design such as CAD/CAM and other drawing software that can facilitate ray-trace simulation. This allows me to deliver precise ray-trace simulations using tools like Zemax/LightTools which meet your specified deliverables. On top of that, I'm no stranger to designs constricted by strict dimensional limitations, which aligns perfectly with your project requirements of an ultra-compact form factor.

@Ryan15222

With my interdisciplinary background in mechanical design, electronics, and software development, I am confident I can offer you the comprehensive and tailored approach needed for your compact LED optical stack design. Boasting extensive CAD design experience, I will ensure your project fulfills both form and function requirements while adhering to demanding physical constraints. Precise integration of mechanical design with electrical and software components is my forte – this particular skill ensures smooth communication between different facets of the system. My ability to take a systems-level perspective and unite different areas of engineering work will be invaluable in devising an optimized yet robust LED optical stack for your illumination needs. My past endeavors have involved numerous tasks similar to yours – efficient use of materials, optimization within tight physical limits, and ensuring long-lasting reliability in harsh environments. Having worked on such demanding projects, including medical appliances, I am keen to apply my learnings and experience to deliver the top-notch compact LED optical stack you seek.

@gzarali

Hi, I’m a multidisciplinary engineer focused on design + analysis, delivering production ready CAD and simulation-backed solutions. I work across mechanical and architectural scopes, with clear drawings, practical detailing, and fast communication. Feel free to check my profile for similar projects ,happy to review your scope and suggest the best next steps. G. Zaralı

@sakshis576

As a highly skilled and versatile professional, I can integrate my expertise in CAD/CAM, Engineering, Mechanical Design, Mechanical Engineering, 3D Modelling, Solidworks, and Keyshot among others into this Optical Stack Design project. I have successfully undertaken similar projects which required optimally designing precise, compact optical assemblies. Furthermore, my background in structural design and calculations also gives me an upper hand in ensuring that your project's mechanical constraints are met with utmost precision. Given your emphasis on high output and reliability - essential aspects not only for medical applications but across industries including harsh industrial environments - my experience with precision systems will come into great play in exceeding your expectations. My commitment to efficiency guarantees that I would eagerly explore innovative ways to enhance the stack design while maintaining the high uniformity beam profile you seek and keeping within your specific diameters and length limits.

@muhannadbukhamse

Hello this is Mohand, a talented mechanical engineer with strong experience in precision mechanical design and optical system integration. I’m excited about the opportunity to work on your “Compact LED Optical Stack Design” because it matches my background in compact mechanism design, thermal considerations, and performance-driven engineering. I can develop a compact LED optical stack that targets a uniform, sharp-edged My workflow includes ray-trace simulation in Zemax or LightTools, optical sequence optimization with off-the-shelf components where possible, and thermal resistance review to support stable performance. I have experience working on tight-tolerance assemblies where optical efficiency, packaging, and heat control must all work together, especially in high-reliability applications. I can also coordinate design iterations quickly and provide clear milestone updates so you can review the optical concept before finalizing the stack. If you share the requirements document, I can start immediately and help refine a practical, manufacturable solution for this illumination project.

@hayat38402

Hi, how are you doing? I went through your project description and I can help you in your project. your project requirements perfectly match my expertise. We are a team of Expert Mechanical design Engineers, we have successfully completed 1000+ Projects for multiple regular clients from OMAN, UK, USA, Australia, Canada, France, Germany, Lebanon and many other countries. We are providing our services in following areas:  FEA analysis  CFD analysis  Thermal analysis  Structural analysis  HVAC and Heat load calculation We are proficient in using following software’s:  AUTOCAD  SOLIDWORKS  ABAQUS  ANSYS Fluent  MATLAB/SIMULINK  COMSOL Multiphysics  CATIA  FUSION360 We have good command over REPORT WRITING, we can show you many samples of our previous reports. We can discuss further details in the message box.

@thanhbinh160886

I am here to bring your product to life. I'm a mechanical engineer with 11 years of experience designing industrial product, furniture product, plastic product and machine, automatic system Experience type: 3D, 2D models, Render, Sheet Metals, Machines and Devices, Industrial Products, Plastic Molds, Plastic Parts Software program: Autodesk Inventor, Solidworks, Autocad , NX-Siemens I am always glad to cooperate, I guarantee quick lead-time, information of the project is always confidential . Your project will be developed with speed and high quality, as well as all the jobs already accomplished. Please send me a message.

@samaraju911

I can support the development of your compact LED optical stack and deliver a high-efficiency, manufacturable solution within your tight mechanical envelope. With over 9 years of experience in precision optical system design—including compact, high-performance assemblies for aerospace and electro-optical applications—I’m well-versed in balancing beam shaping, efficiency, and thermal constraints. Your requirement for a uniform, sharp-edged 150 mm beam at 650 mm throw using a high-CRI emitter like SST-20 is achievable through a carefully optimized lens stack or hybrid refractive/freeform approach. I will perform detailed ray-trace simulations in Zemax OpticStudio, optimize for uniformity and edge sharpness, and propose an optical sequence prioritizing off-the-shelf components where feasible to reduce cost and lead time. I’m confident in delivering a robust, compact design aligned with your performance and manufacturability goals, and I’d be happy to review your detailed requirements document to proceed further.

@antonk52

As an experienced and versatile developer, I am excited to expand my skillset into your project of Compact LED Optical Stack Design. Although my expertise lies in web, mobile and game development, I also have a deep comprehension in CAD/CAM, Mechanical Design and Mechanical Engineering; which I believe would suit this optical stack design task. While my previous work does not exclusively feature medical or harsh industrial optical designs, my knowledge in precision systems and experience with diverse technologies has allowed me to deliver efficient and reliable solutions time and again. Additionally, my proficiency with ray-trace simulations using Zemax/LightTools will play an essential role in delivering the thermal resistance specs you require. Also, my appreciation for off-the-shelf parts utilization where possible is a cost-effective approach that aligns with the deliverables of this project. I would be thrilled to share more about how I intend to push efficiency and reliability further while working on the project if given the opportunity.

@timothyw68

Hi, how are you doing? I’m very interested in supporting your compact LED optical stack design and achieving a clean, uniform beam within tight constraints. I have experience working with precision optical systems, ray-tracing workflows, and integrating LED sources into efficient, compact assemblies. I would approach this by modeling the system in Zemax or LightTools, optimizing the optical path (lenses/diffusers/collimators) to achieve the 150mm sharp-edged beam at 650mm while respecting your size limits. I’ll prioritize off-the-shelf components where possible, validate uniformity and edge definition through simulations, and include thermal considerations to ensure stable performance with the SST-20 emitter. I focus on balancing optical performance, manufacturability, and reliability, and I’d be happy to review your full requirements and refine the design with you. Best regards, Timothy

@damirs6

Hello, Achieving a uniform, sharp-edged 150 mm beam at a 650 mm throw within a 39 mm optical stack will mainly depend on controlling beam shaping and minimizing edge roll-off from the LED emitter. My approach would begin with modeling the SST-20 emitter profile in Zemax, including its Lambertian distribution and source size. From there, I would evaluate a compact collimation + beam-shaping stage, typically using a short focal-length TIR optic or hybrid lens combined with a secondary shaping element to control edge sharpness. Because the stack length is restricted, the design would likely rely on efficient primary collimation with minimal optical surfaces, followed by a field-shaping optic to produce the required 150 mm illumination circle. Thermal considerations are also important with high-CRI LEDs, so I would estimate junction temperature impact on output and efficiency and provide thermal resistance guidance for the mounting interface. Deliverables would include ray-trace simulations, optical layout, recommended off-the-shelf components where possible, and performance verification plots. I would be glad to review the requirements document and refine the optical sequence accordingly.

@suttonp

Hi, Designing a compact illumination system with a well-defined beam edge is primarily a beam-shaping problem. The main challenges here are controlling divergence from the LED and maintaining uniform intensity across the 150 mm spot. I would start by building a ray-trace model of the SST-20 emitter in Zemax, then evaluate a compact optical stack consisting of: • A high-efficiency primary collimator (TIR or aspheric lens) • A secondary shaping optic to control beam diameter and edge definition • Mechanical spacing optimized to stay within the 39 mm length constraint To achieve uniformity, the simulation would examine intensity distribution, edge falloff, and optical efficiency, ensuring the final beam meets the target geometry at 650 mm. I would also provide thermal considerations for the LED mounting interface, since thermal stability directly impacts optical consistency. Final deliverables include ray-trace models, optical sequence recommendations, and performance analysis using off-the-shelf components whenever feasible. Best regards.

@zakaiw

Hello, The key challenge in this project is producing a uniform 150 mm beam with a sharp boundary while keeping the optical stack extremely compact. I would model the SST-20 emitter in Zemax and evaluate a combination of high-efficiency collimation and secondary beam shaping to achieve the required beam profile at 650 mm. The design process would include: • Ray-trace simulations to validate beam uniformity • Optimization of the optical sequence to stay within the 39 mm stack limit • Selection of off-the-shelf optics where possible • Thermal resistance considerations for stable LED performance Deliverables would include the simulation results, optical configuration, and recommended components for implementation.

@alexanderc235

Greetings, Producing a well-defined illumination circle from a compact LED optical stack requires careful control of the emitter geometry and collimation strategy. My process would start with accurate LED source modeling in Zemax, followed by optimization of a compact optical train. Given the dimensional limits, a short focal-length collimator combined with a shaping optic would likely provide the most efficient solution. Special attention would be given to: • Maintaining uniform irradiance across the beam • Minimizing optical losses and stray light • Achieving a clean beam boundary at the target distance Thermal resistance and mechanical spacing will also be evaluated to ensure stable operation in real-world conditions. The final package would include ray-trace simulations, optical layout, and component recommendations suitable for prototyping or production. Kind regards.

@johna049

⭐⭐⭐Optical Design & Illumination System Engineering⭐⭐⭐ Hello Client, I just received a notification from Bark that your project is a great match for my expertise. With hands-on experience in precision optical design and non-imaging illumination systems, I focus on delivering efficient, buildable designs that move smoothly from concept through simulation and into manufacturable assemblies. From your description, the main priority is achieving a compact LED optical stack that produces a uniform, sharp-edged 150mm beam at a 650mm throw distance within very tight mechanical constraints. I plan to address this by combining ray-traced non-imaging optics design with carefully selected off-the-shelf collimation and beam-shaping elements, optimizing for both beam uniformity and packaging efficiency while maintaining thermal and optical stability. What I will provide: 1️⃣ Full ray-trace simulation model (Zemax / LightTools) with performance validation 2️⃣ Optimized optical stack design using readily available lenses/diffusers where possible 3️⃣ Component-level BOM with mechanical stack-up and thermal resistance considerations If you're looking for dependable optical engineering support with a strong focus on manufacturable, high-performance illumination systems, I’d be glad to collaborate. Sincerely, John

@griffinl5

Hello, This is an interesting optical challenge, especially with the tight mechanical constraints. Achieving a uniform 150 mm beam with a sharp edge at 650 mm using the SST-20 emitter will require careful control of the emitter divergence and an efficient collimation stage. I would begin by modeling the LED source in Zemax, then optimize a compact collimator + beam shaping optic that stays within the 39 mm × 20 mm stack envelope. The goal would be maximizing uniformity and optical efficiency while maintaining a clean beam boundary. I can deliver ray-trace simulations, optical layout, and recommended off-the-shelf components. Best regards,

@maximop0

Hi, Designing a compact LED optical stack with a defined illumination footprint is primarily a beam-shaping problem. With the SST-20 emitter, the main task will be controlling divergence while maintaining uniform irradiance across the 150 mm beam. My approach would be to first create an accurate Zemax model of the LED emitter, then evaluate a compact optical sequence that fits within the ≤39 mm stack length. Typically this involves a primary collimator (TIR or aspheric lens) followed by a secondary shaping element to control the beam diameter and edge definition at the 650 mm throw distance. During optimization I would evaluate beam uniformity, efficiency, and edge roll-off, ensuring the design meets the illumination requirement while staying within the mechanical constraints. Deliverables would include ray-trace simulations, optical configuration, recommended off-the-shelf optics, and thermal considerations for LED mounting. Looking forward to reviewing the full requirements document.