Developing custom luminaires: from idea to prototype

Key facts in brief: A custom luminaire is created in five steps: specification, optical and thermal design, prototype, photometric measurement and proof of conformity. The basis for safety is the IEC 60598 series, whose Part 1 (edition 2022-03) governs marking, mechanical and electrical construction and photobiological safety.

When a custom luminaire makes sense

When catalogue luminaires do not match the architecture, dimensions, light distribution or brand image: light-integrated furniture and interior elements, luminaires for listed buildings, corporate design luminaires or special applications with particular optical requirements.

The development steps

Specification: lighting task, desired light distribution, luminous flux, colour temperature, colour rendering, glare limitation, dimensions, installation situation, protection rating, quantity, target costs.
Optical design: selection of LED, lens, reflector or diffuser; simulation of the luminous intensity distribution. This is where efficiency and glare are decided.
Thermal and electrical design: LED service life depends strongly on temperature. Heat sink, driver and dimming interface (e.g. DALI) are coordinated.
Prototype: functional sample from 3D printing, CNC or small-series parts; on-site sampling.
Measurement and data: measurement of the luminous intensity distribution and creation of planning data so that the luminaire can be calculated in DIALux or Relux.

Standards and conformity

Luminaires up to 1,000 V must meet the safety requirements of the IEC 60598 series. Part 1 sets out the basic requirements and tests – classification, marking, mechanical and electrical construction and photobiological safety – and always applies together with the relevant Part 2 for the respective type of luminaire ^[1]. For placing on the EU market, CE marking with the relevant EU directives (including Low Voltage, Electromagnetic Compatibility, RoHS) and the ecodesign requirements for light sources must also be taken into account. Which tests are specifically required is clarified in the specification with the manufacturer or test institute.

The current edition is DIN EN IEC 60598-1 (VDE 0711-1):2022-03, the German version of EN IEC 60598-1:2021 based on IEC 60598-1:2020; it was supplemented by amendment A11:2023-01 and corrected in 2023 ^[1] ^[2]. The standard applies to luminaires up to 1,000 V and always together with the relevant Part 2 for the type of luminaire; a draft revision has been available since 2024-03 ^[2]. The ecodesign requirements of Regulation (EU) 2019/2020 also apply to light sources and separate control gear placed on the market in a containing product – i.e. in the luminaire ^[3].

Result of the development

Specification and documented design decisions
Optical and mechanical design data, bills of materials and production documents
Measurement reports on luminous intensity distribution and luminous flux
Planning data in EULUMDAT (LDT) and IES format for DIALux and Relux
Technical documentation as the basis for the manufacturer's testing and declaration of conformity

The advantage of optical engineering

Most errors arise at the interface between design and physics: a beautiful shape that dazzles, or efficient optics that do not fit into the component. Combining optical design and lighting design means developing the luminaire from the lighting task.

Frequently asked questions

Is a custom luminaire worthwhile for small quantities?

Often yes, for example as a conversion or adaptation of existing luminaires. We clarify the economic viability in a short feasibility study.

Do you handle CE certification?

We support development in compliance with standards and prepare the technical documentation. Testing and declaration are carried out by the manufacturer or test body.

What data do we receive at the end?

Specification, optical and mechanical design data, measurement reports and planning data (LDT/IES) with which the luminaire can be calculated in DIALux and Relux.

Sources (in German)

Author: Paul Rostand Ndjeundoun, M.Sc. (Hons), Certified Lighting Expert (LiTG), Registered European Lighting Expert · As of November 2026. Standard values have been carefully researched but do not replace consulting the currently valid edition of the standard.