Our design method considers not only optical function and performance, but also responds to mechanical and production requirements. Real world conditions including prototyping, tooling, polishing, molding, vacuum metalizing, and assembly influence final design.

We design:  Lenses,  Reflectors,  Light Guides & Pipes,  Total Internal Reflectors (TIRs),  Backlights, Other Optical Components

Sources:   LEDs,  Halogen,  HID,  Fluorescent,  Incandescent,  Induction,  Infrared Sources

Materials:  Acrylic,  Polycarbonate,  Silicone,  Glass,  Metal

We design in LucidShape, a simulation software with powerful parametric design tools integrated into the simulation environment, or in Rhino or other CAD software. Final and progress designs can be exchanged through STEP, IGES, or other CAD formats. Design reports can include two-dimensional drawings, specifications, simulated photometric data, and other schematics as required.

Charlevoix Design uses simulation software to evaluate optical performance of a lamp design before incurring prototype & production costs. The software we use not only provides crucial feedback on a design, but also has powerful tools to efficiently create optical components directly in the simulation environment.

Simulation software:  LucidShape,  TracePro, Visual, Dialux, Maxwell Render

Real world conditions such as positioning tolerances, source binning, and tooling artifacts, and LED flux binning are taken into account to minimize inaccuracies. Additionally, proper safety factors and margins ensure the best chance of meeting a design’s goals.

Charlevoix Design has three photolabs for lamp testing.

A primary photolab has an automated Type A goniometer with 100′ test tunnel and 25′ beam evaluation screen. This is used for many types of test including automotive exterior.

A second photolab houses a Type C goniometer  for testing of architectural luminaires. There is an additional Type A goniometer with a 25′ test tunnel and beam evaluation screen as well.

For smaller parts or specialized tests, Charlevoix Design has a separate photolab with test benches, optical rails, and three dimensional translators.

Other test equipment includes an integrating sphere, colorimeter, luminance meter, and handheld illuminance meters.

Photometry results, thermal tests, and other evaluations are summarized in standard or customized reports depending on customer needs.

Parts can be produced in small quantities by CNC machining, stereolithogrophy, typical casting, or rapid prototyping methods. Larger quantities of parts are provided using low volume, prototype injection molding. Our expertise in optical products and tools allows us to convey product concept and criteria accurately, assuring prototypes which perform to near production standards.