Design of large-angle distortion-free and spot adjustable LED spot array projector based on microlens array and eyepiece

The spot array projector has long been a challenging and intriguing research focus in the fields of projection and lighting applications. In the current literature, there is a lack of a comprehensive and detailed presentation on the design and analysis method for a spot array generator based on the structure of imaging eyepiece and MLA. We present a novel design and optimization method for a large-angle, distortion-free and spot adjustable LED spot array projector that is composed of an eyepiece, two microlens arrays (MLAs), and a micro-LED array (MLEDA). The eyepiece system is optimized using imaging optical methods to project sub-beams to the target plane with a large angle. The sub-lens of condenser MLA is also optimized using imaging optical methods to refocus the collimating beam and match the numerical aperture (NA) with the eyepiece, and the sub-lens of the collimating MLA is acquired by using simulated annealing (SA) global illumination optics optimization method to achieve collimation and far-field homogenization. The predistortion MLEDA and the MLAs are proposed and implemented by the radial basis function (RBF) interpolation method, which correct the large-angle distortion introduced by the eyepiece. Both near-field and far-field applications can be realized by the proposed system. In the near-field applications, different spot geometries at the near-field target plane can be achieved. In the far-field applications, the power matching of the MLEDA is used to improve far-field uniformity of spot array. Moreover, the predefined-geometry arrangement spot array can be realized in both near and far fields. Two design examples with full field of view (FOV) projection of 80° and 100° are provided to validate the proposed method. Overall, the proposed system offers a promising solution for various applications requiring target identification or 3D calibration.