Optical design

Very Long Lightguide Technology

Following the relatively recent, rapid increase in vehicle interior ambient styling lighting, a new emerging trend for automotive lighting is to accent vehicle exterior styling.


This has already been proposed for smaller areas, such as front grills, badges and air intake bezels, etc., but Polymer Optics Automotive Limited (POAL) has had requests for integrating illumination styling into much longer component paths, such as roof bars, running-boards and vehicle sill panels. POAL has further proposed that long lightguide systems of this kind can also be used on tail gate surrounds, and door aperture thresholds, as well as longer illumination paths for vehicle interiors.


To make these applications cost effective and robust, it is not sufficient to simple use strings of multiple LEDs, so POAL has developed a versatile, customisable, very long lightguide technology, to enable the assembly to be illuminated from both ends of the illuminated feature or even only one end. This approach greatly simplifies the mechanical demands on the system, enabling it to be engineered to be very robust, weather proof and flexible to follow the vehicle contours.

POAL has taken its well developed lightguiding techniques and further develop them to be able to make lightguide products of up to 2m length or greater. This has required POAL to develop new light control patterning techniques and in-house write new software routines to generate the light control patterns ready for the manufacturing processes.

Since the product assemblies are very long and of relatively small cross-section, the manufacturing routes lend themselves to precision optical extrusion, which reduces tooling costs and product manufacturing costs. This approach also enables a very flexible design opportunity for the outer format of the assembled product, so that integration to the target vehicle can be simplified. Also, the opto-mechanical configuration developed by POAL provides a wide range of candidate materials to be considered, so the chemical and mechanical robustness of the product can be tuned to the vehicle specifications and balanced against the final product cost.

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