At CES 2025, LG is unveiling two new projectors: the PF600U and the CineBeam S. These devices showcase impressive features like ultra-short throw projection, integrated Bluetooth speakers, and AI-driven auto-calibration—all packed into portable designs. For design engineers, this raises the question: how do you actually engineer such a product?
Creating a projector like the CineBeam S involves intricate engineering across multiple disciplines. Each component—optics, electronics, mechanical systems, and software—must work seamlessly. This article breaks down the process of designing an advanced projector while referencing real-world engineering practices from Sony, Texas Instruments, and Dyson.
Defining Requirements
The engineering process begins with defining the functional and technical requirements. For a device like LG’s CineBeam S, these could include:
- Image Quality: High resolution (e.g., 4K UHD) and sufficient brightness (500 ANSI lumens for CineBeam S).
- Portability: Lightweight design for mobility (CineBeam S weighs 5.5 pounds).
- Functionality: Features like short-throw projection, AI-driven auto-calibration, and Dolby Atmos capability.
Engineers collaborate with marketing teams to align user needs with feasible design goals. Early feasibility studies assess whether existing technologies—such as Texas Instruments’ DLP (Digital Light Processing) chips—can meet these requirements.
System-Level Design
Once the requirements are clear, engineers develop a system-level architecture. This involves breaking down the design into subsystems:
- Optical Subsystem:
- Short-throw lenses require precise geometry to minimize distortion. Sony has shared insights into designing ultra-short throw optics, emphasizing challenges like keystone correction and edge-to-edge clarity.
- Light sources, such as LEDs or lasers, must be chosen based on brightness, efficiency, and heat management.
- Electronic Subsystem:
- Processing units handle tasks like video rendering, auto-calibration, and connectivity. For instance, LG’s webOS platform supports streaming and AI features.
- Connectivity modules for Wi-Fi and Bluetooth enable additional functionality, like streaming audio to external devices.
- Mechanical Subsystem:
- Portable designs require lightweight materials and efficient cooling mechanisms. Dyson’s engineering practices emphasize prototyping to balance performance and durability.
Prototyping and Integration
Iterative Prototyping
Engineers start with prototypes to validate core functionalities. Early models might test:
- Brightness and resolution under varying conditions.
- Keystone correction and image alignment features.
Dyson’s approach to prototyping—extensive testing and refinement—ensures reliability before full-scale production.
Subsystem Integration
Bringing optical, electronic, and mechanical systems together is challenging. For example:
- Thermal Management: Compact projectors generate heat, so efficient cooling solutions like heat sinks or silent fans are critical.
- Precision Alignment: Advanced tools such as optical ray tracing software help ensure lenses and imaging panels are aligned for optimal performance.
Manufacturing and Refinement
Design for Manufacturability
As the design nears completion, engineers optimize it for production. This includes:
- Selecting components that balance performance with cost efficiency.
- Simplifying assembly processes to reduce production time.
Quality Control
Rigorous testing ensures the final product meets specifications. For projectors, this includes:
- Image Testing: Verifying brightness, resolution, and color accuracy.
- Durability Testing: Evaluating resistance to environmental factors, such as temperature changes and vibrations.
Texas Instruments’ DLP technology is a benchmark for high-quality optical performance, demonstrating the importance of precise component integration.
Key Technologies Driving Design
Several advanced technologies enable the features seen in modern projectors:
- Short-Throw Lens Technology:
- Engineers use specialized lens geometries to achieve large images from minimal distances. Sony’s work in this area highlights how to overcome challenges like minimizing distortion.
- AI-Driven Auto-Calibration:
- Features like LG’s auto-alignment and wall color adaptation rely on machine learning algorithms. These systems analyze room conditions and adjust settings in real time.
- Integrated Connectivity:
- Wi-Fi and Bluetooth modules are standard, enabling seamless streaming and integration with other devices.
Conclusion
Engineering a high-tech projector like those unveiled at CES 2025 requires meticulous planning and collaboration across disciplines. From defining requirements to refining for manufacturability, every step involves balancing technical constraints with user expectations. Companies like Sony, Texas Instruments, and Dyson exemplify how rigorous engineering practices lead to innovative products.
By understanding the technologies and processes behind these devices, design engineers can gain valuable insights into creating their own cutting-edge solutions.
