reflector design

Designing the optimal reflector with experience and expertise.

Flexibility, precision and speed are crucial for ACL-Lichttechnik GmbH when solving photometric requirements. This and more than 35 years of experience in the field of reflector design are appreciated by a constantly increasing number of customers who ask us to design stand-alone reflectors or entire reflector series.


Besides the LED module the reflector represents the fundamental part of a luminaire mainly determining its beam spread and its light output ratio. In order to achieve the highest light output ratio possible, the design of a reflector has to be based on the physical and photometric characteristics of the LED module used as well as on the type of luminaire and its physical and thermal properties. The result of the design process is a high-efficiency reflector with a specified beam spread optimally adapted to the luminaire.

3D Reflector Design
3D Reflector Design

ACL-Lichttechnik GmbH accomodates the gaining importance of Light Emitting Diodes (LED) in lighting by using special LED reflector design tools in combination with the long-lasting experíence of our constructing engineers to realize LED reflectors with optimal light directing properties.


As the design is only the first step on the way to the final product splitting your product development orders up on different suppliers could cause coordination and responsibility problems. ACL-Lichttechnik GmbH makes sure that the final reflector fully matches the designed reflector because ACL also controls the whole process of manufacture including the accurate production of the tooling (if a tool is necessary at all).


The design process of e.g. a round reflector includes the following steps:

  1. Customer provides ACL-Lichttechnik GmbH with technical and photometric details, e.g. type of LED module, diameter light input opening, diameter of light output opening, maximum and minimum dimensions of required reflector, required beam spread or diameter of light cone at a special distance to the reflector etc.
  2. Calculation and photometric evaluation of the reflector shape with the help of individual software modules developed in-house and photometric analysis programmes, transfering the results to a 3D CAD software and creating a detailed technical drawing of the reflector prototype.
  3. Emailing the technical drawing (in DWG, DXF, STEP or IGES format) to the customer.
  4. Manufacture of the spinning tool upon receipt of the customer‘s approval of the technical drawing.
  5. Manufacture of a prototype on the spinning tool.
  6. Photometric in-house testing of the prototype or testing by an independent external lab.
  7. Shipping of one or several prototypes approved by ACL-Lichttechnik GmbH to the customer.
  8. Manufacture of further tools necessary for the pilot production starts upon the customer‘s approval.
  9. The customer can intervene in the design process at any time asking for modifications or optimisations which can be put into practice in a very short time.
Light Cone Diagram
Light Cone Diagram

All these steps require between one and three weeks depending on the degree of complexity of the reflector. In contrast to spun round reflectors there are normally no special tools necessary for the production of rectangular and square reflectors (including linear reflectors and louvres) during the design process. Prototypes and samples can be lasered out of preanodised aluminium or produced using existing punching, bending or stamping tools.

Benefit from the more than 35 years of experience of ACL-Lichttechnik GmbH in the field of reflector design and reflector manufacture. Trust in the design skills of our technical engineering team and take the opportunity to get design and manufacture from one single source.

By the way: the design process could also include our support in finding a reasonable and simple way of fixing the reflector to the LED holder or luminaire fitting.