Optical performance and manufacturing feasibility of a novel retroreflective geometry

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The industrial partner of the present proposal, Active Industrial Solutions, represents a well-established name on the North American market focused on the fabrication of production of prototype as well as production moulds, process fixtures, inspection gauges, and all forms of secondary assembly equipment. From its inception in 1977, the company has experienced a sustained growth, primarily due to its innovation-driven focus that has facilitated its continuous expansion well beyond its initial involvement with the fabrication of moulds for the automotive sector. Among the technologies that were considerably expanded and enhanced over the years by Active Industrial Solutions, the fabrication of moulds for automotive lighting occupies the front stage. In this regard, it will be briefly mentioned here that Active Reflex Solutions, Active Industrial Solutions's division specialized on lighting products for automotive and traffic applications, relies on the most advanced technology in the design and manufacturing of reflective optical inserts, including an 100-foot light tunnel. Active Reflex Solutions is actively seeking to identify innovative retroreflective products that will allow a further advancement of its business on the global market. To address this, the present proposal will aim to identify the technical and economic viability of a novel prismatic retroreflective geometry that departs significantly from the current state-of-the-art in the field. Through a combination of theoretical/mathematical modeling, optical simulations and single point inverted cutting performed by means of a diamond tool mounted on a five-axis micromilling machine, the research team will attempt to model, fabricate and validate the newly developed retroreflective geometry. If successful, the proposed research will strengthen Active Industrial Solutions's position as a market leader in the area of illumination/lighting products, and will open up new avenues of collaboration between Active Industrial Solutions and Western.