Advanced FMLAs for next generation headlights
Free-form micro-optics (FFMOs) offer high design freedom and significant potential to reduce installation space and weight while enabling more energy-efficient optical systems. FORVIA HELLA, one of the larger automotive suppliers worldwide, worked with PHABULOuS to test several optical designs toward developing the next generation headlamps based on free-form micro-optics. The latest demonstrator highlights impressive improvements towards a highly compact and thin FFMO-based solution for low beam applications.
Innovative design for next-generation headlights
Free-form micro-optics enable a new level of freedom in headlamp design. They allow thinner, lighter, and more efficient optical systems with excellent light performance. In FORVIA HELLA’s latest developments, several optical designs were tested and demonstrated, showing remarkable progress and highlighting the extremely low thickness achievable with an FFMO-based approach. The design concept focuses on a double-sided free-form optic. The light entrance side pre-forms the beam, while the light output side sculpts the final light distribution using structures such as micro-facets, Fresnel-like surfaces, or fully free-form geometries. The result is a refined and compact optical element designed specifically for low-beam applications.
Latest design of a double-sided FFMO realizing a low beam distribution
From precision mastering to replication
Through advanced ultra-precision machining and laser-based processing techniques, the optical masters were created with high accuracy and impressive surface quality. The free-form structures were optimized through several iterations to match the simulations perfectly. The replication phase confirmed that both optical surfaces – entrance and exit – could be combined into a single, double-sided component. The resulting prototypes were integrated into a functional demonstrator, proving that free-form micro-optics can deliver excellent performance while significantly reducing the overall size and weight of headlamp systems.
The final demonstrator with a vertical modular design, realized by FORVIA HELLA with the optics as shown above
Towards compact and efficient automotive optics
Starting with a research-level concept, FORVIA HELLA demonstrated the potential of free-form micro-optics for automotive headlights in an application-oriented setup. By bundling the knowledge and experience of various PHABULOuS partners, value was added for the rapid development and production of the optical components. By applying the benefits of free-form micro-optics to headlamp design, significant progress was achieved, highlighting the extremely low thickness of the FFMO-based approach. With these promising results, FORVIA HELLA is continuing to drive developments with FFMOs beyond the PHABULOuS project.
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“We started with a research-level concept and demonstrated the potential of free-form micro-optics for automotive headlights in an application-oriented setup. PHABULOuS offers enormous added value for the rapid development and production of FFMOs by bundling knowledge and experience.” Dr. Daniela Karthaus, Optical Engineer at FORVIA HELLA |
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