Design and fabrication of freeform reflector for automotive headlamp

Modern automotive illumination systems require higher efficiency, safety, and good aesthetic features. The design, fabrication and measurement are critical issues for automotive illumination systems. The non-imaging optical design for the automotive lighting system, which departs from the methods of traditional optical design, is an arisen interdisciplinary field. In order to meet the traffic regulations, unique freeform shapes and geometries should be adopted to create the special legal light pattern. Mean while, high accuracy freeform reflector could not be made by conventional manufacturing process, ultra-precision machining is the method. And the measurement of the freeform surface is also a new area. In this paper, the optical design, fabrication and the measurement of the freeform reflector headlamps are investigated.