Free-form surface design method for a collimator TIR lens

A free-form (FF) surface design method is proposed for a general axial-symmetrical collimator system consisting of a light source and a total internal reflection lens with two coupled FF boundary surfaces. The profiles of the boundary surfaces are designed using a FF surface construction method such that each incident ray is directed (refracted and reflected) in such a way as to form a specified image pattern on the target plane. The light ray paths within the system are analyzed using an exact analytical model and a skew-ray tracing approach. In addition, the validity of the proposed FF design method is demonstrated by means of ZEMAX simulations. It is shown that the illumination distribution formed on the target plane is in good agreement with that specified by the user. The proposed surface construction method is mathematically straightforward and easily implemented in computer code. As such, it provides a useful tool for the design and analysis of general axial-symmetrical optical systems.