Polymer Optics Automotive Limited (POAL) is a wholly owned subsidiary of Polymer Optics Limited (POL)
POAL was set up to concentrate its expertise in optical product design, development, tooling and mass manufacture in the automotive market, supporting OEMs and 1st and 2nd Tier suppliers. This allows POAL to specifically resource and support the automotive industry, but draws on POL’s many years of product and process development and innovative approach. This has resulted in many patented techniques developed for automotive applications.
POAL’s wide expertise in product design, assembly and manufacture enables us to apply advance Design for Manufacture (DFM) techniques to build in product reliability and dramatically reduce cost in tooling and product. On many projects, POAL is able to reduce component counts in assemblies, speed assembly times and remove complex tooling features, while improving the optical efficiency and overall illumination performance of the system.
POAL fully manages and supports the mass manufacture of automotive lighting products, together with the associated surrounding parts of the assembly, through carefully selected localised supply-chains. These supply chains are built and managed by POAL to provide a wide range of process capabilities to supply innovative lighting products, with TS approved manufacturing partners. This gives us very wide flexibility in the technologies we employ in our leading edge product designs.
| Original customer design used two injection moulded white reflectors to try to contain the light in the system
||POL re-design uses a die-cut reflective polyester film to give a more efficient, low cost construction|
|Light bleed at top of display and poor contrast||Light bleed removed and contrast enhanced|
|Original Customer Lightguide||High level of light-bleed in the original customer design|
|New POL Lightguide||Dramatically reduced stray light in the POL design giving higher contrast display|
|POL has developed the interior illumination system for the 2014 Nissan Qashqai which draws on POL’s wide polymer optical product development experience to introduce some novel product features
|The lightguide was designed with advanced light control features and textures to independently control and adjust the illumination in the upper and lower sections, to achieve the required evenness and balance.POL has patented new light control techniques to give fine control over the viewing angle, direction and evenness of the illumination projected onto contoured target surfaces in automotive and other similar applications.|
POL has developed the interior lighting for the recently released Infiniti Q30 range of vehicles, including the cup-holder illumination, dash-board accent illumination and foot-well interior lights.
We supported the vehicle development with full opto-mechanical design and analyses of the lightguide assemblies, prototyping and tooling stages, through to on-going mass manufacture.
Again, POL’s advanced DFA techniques were employed for ease of manufacture and assembly, with full Poke Yoke capability, especially for the Interior Light product where the number of components and tooling complexity was greatly reduced over the customer’s design.
|POL has developed the 350mm long lightguide assembly to project light onto the edge of the lower dashboard section for accent illumination. The light output is controlled with fine light extraction feature patterns to give the required light distribution along the grained finish of the dashboard contours.|
The latest computer optical design and ray trace programs with optomechanical innovation are used to take full advantage of plastics materials. Complex optical surfaces combined with integral low cost assembly features.
SLA (Stereolithography), SLS (Selective Laser Sintering), Clear SLA, SLA to Vacuum Casting, Direct Machining and Tooling options.
Proven optical quality toolmakers are chosen and assisted by mould flow analysis to optimize the tool. Our specialist toolmakers are skilled in optical surface generation and polishing.
Our moulders are trained in the art of optical moulding. Mould flow process analysis and thorough F.M.E.A. is controlled by the Project Manager to ensure quality and quantity.
Our integrated approach to design enables optical components to become part of the total solution, including how they interface with the other non-optical components.
Plastics optical components can be coated in poly-siloxane and acrylate based resin blends to impart more robust properties.
Polymer Optics “Modular LED Optics”® design, based on a patented hexagonal format, allows maximum packing density and assembly flexibility for a wide range of applications.
We have also developed specialist optics for the latest range of high power UV LEDs emerging onto the market. These are made from high quality optical silicone to give excellent UV transmission with no long term degradation. See POL’s Silicone Optics page for further details.
We design and supply a comprehensive range of high quality, standard products for use with most world-leading LED devices
Hybrid Reflector design uses a central lens to collect and collimate the on-axis light from the LED.
Our expertise in efficient light control in Lightguide assemblies, enables a lower number of LEDs to achieve the maximum performance.
Free-Form optics are a relatively recent development which offer a step change in the way wide areas are illuminated by LEDs.
Our "engineering with light" approach allows us to provide product solutions for all applications across the whole spectrum from Visible to Infrared.
Developed tooling techniques enable us to produce precision optical surfaces with optical apertures of less than 1mm in diameter, required for miniature camera lens applications.
Our design approach, using light scattering pattern techniques, have enabled us to provide high efficiency display illuminations with very compact space envelopes, which use the minimum of light sources and electrical power consumption.
Our experience in designing and developing ophthalmic products, enables us to provide precision, impact resistant, eye protection optics for applications such as: fire protection, motor cycle visors, industrial PPE and military systems.
Polymer Optics have designed and manufactured a range of optics for street lighting, to meet both the ME and S class regimes of EN13201-2 in Europe and the requirements of IESNA RP-8-00 in the USA.
Emergency Lighting and Visual Alarm Devices are applications where light from an LED has to be efficiently distributed over a wide area. POL’s free form optics technology is particularly suited for applications which require wide area illumination.
POL can now provide advanced optical product design and rapid manufacture in the latest silicone resins to gain design and cost advantages in our customers’ applications.
Our patented prismatic colour mixing optic was introduced to enable good colour mixing, for narrow beam angle systems, using three discrete LED sources.
Brand named “GloWorm®”, the novel lightguide technology enables the light projected from a simple lightguide to be redirected and shaped
Opto-mechanical design and analyses of lightguide assemblies, prototyping and tooling stages, through to on-going mass manufacture.