Optical design

Hybrid Reflectors


To see the complete range of POL Hybrid Reflector Optics for specific LED packages
LED Optics

hr1  Conventional reflectors manage to control the off-axis light from the source, but don’t control the light that misses the top edge of the reflector, so a lot of light is wasted into a halo around the central spot beam.  hr2
  The POL Hybrid Reflector design uses a central lens to collect and collimate the on-axis light from the LED.In this way, the light collection efficiency can be driven up to >90% with a more controlled, narrower, higher intensity beam.  hr4

To make the Hybrid Reflector products, POL has developed a novel in-mould production process to make the reflector and integration features in one process and provide easy assembly of the central lens and modular LED mounting.

Highly reflective metal shim used with 95-98% reflectivity.

Hard anodized metal has very good chemical resistance and scratch resistance.


 hr5Flat die-cut reflective metal hr6Metal shim pressed into shape in mould tool  hr7Support frame and mounting features injection moulded around metal hr8Central lens clipped in place and LED mounting assembled
hr9 The perfect colour mixing can be achieved with the POL Colour Mixer Hybrid Reflector optics, allowing an infinite range of illumination colours to be produced with a constant and stable beam geometry.An additional advantage is that the appearance of the emitted light from the optic is a uniform mixed colour too, removing the usual visible spots of RGB seen in other colour mixing approaches.


POL also produce reflector products by conventional metal spinning and using vacuum metallisation of plastic moulded reflector substrates, but similarly POL can integrate the Hybrid Reflector central lens component into these other production routes.


An additional modular design approach is to use beam converter optics fitted over the standard reflectors to give different beam angles . This approach gives a modular, flexible product design with the minimum number of component parts. The beam converter optics are either supplier pre-assembled to the base reflector product or can be supplied separately, so that customers can customise product assemblies at point of manufacture or point of installation.


The POL Hybrid Reflector products can also be fitted with a novel optical integrator design to provide beam smoothing and colour variation mixing with multi-die and COB LED arrays.


This technique can also give a constant beam angle using the same 60mm reflector form factor, with which ever LED array size is used or can give different beam angles with the same 60mm reflector form factor, using the same LED array size. In this way very versatile and modular lighting systems can be produced.


The novel POL optical integrator design approach also allows simple modular lighting products to be developed:Components snap-fit together to produce a modular assembly
Allows point of assembly or point of installation customisation
Range of beam angles and system powers made from same base parts – same reflector, light engine format and adaptor
The only component that has to be changed to produce different beam angles and beam shapes is the integrator-converter


Optical ServicesServices

Design and Development

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.


Global Manufacturing

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.


Technical Development

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.


Optical Coatings and Films

Plastics optical components can be coated in poly-siloxane and acrylate based resin blends to impart more robust properties.


Project Management

Every project has a dedicated Manager to ensure as tasks are actioned, the client is kept informed on progress at each stage. Timing plans are used to monitor progress against agreed milestones and they ensure full control through-out the design, tooling, sampling and production stages.


  • Design and Development
  • Prototyping
  • Tooling
  • Global Manufacturing
  • Technical Development
  • Optical Coatings and Films
  • Project Management