SWIR vs. FIR: What Is the Difference Between Short-Wave Infrared and PIR Thermal Infrared?

Last Updated: July 24, 2026
Author: Myungjoong Kim, CEO, Fresnel Factory Inc.
Reading Time: Approximately 10 minutes

Quick Answer

SWIR and the infrared band used by PIR motion sensors are both outside the visible spectrum, but they operate as almost entirely different technologies.

  1. SWIR systems typically operate from approximately 0.9 to 1.7 µm and usually image reflected or transmitted light.
  2. PIR motion sensors typically detect thermal radiation near 8–14 µm, which is more accurately described as LWIR or thermal infrared.
  3. SWIR commonly uses InGaAs detectors, while PIR sensors use pyroelectric elements.
  4. A SWIR system may require sunlight, an LED, or a laser illuminator. PIR sensors detect radiation emitted by people without active illumination.
  5. SWIR and 8–14 µm systems require different detectors, optical materials, lens geometries, manufacturing tolerances, and evaluation methods.

The term “FIR lens” is widely used in the PIR motion-sensor industry, but specifying the actual operating wavelength—usually 8–14 µm—is more technically accurate.

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Why Is the Term “FIR” Confusing in the PIR Industry?

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Infrared wavelength terminology is not completely harmonized across optics, remote sensing, thermal imaging, telecommunications, and sensor manufacturing.

A practical engineering classification is:

Band Common Practical Range Typical Applications
NIR Approximately 0.75–1.0 µm 850 nm and 940 nm illumination, 905 nm LiDAR, ToF, and 3D sensing
SWIR Typically 0.9–1.7 µm InGaAs imaging, inspection, spectroscopy, and 1,550 nm systems
Extended SWIR Up to approximately 2.5–2.6 µm Chemical analysis and extended-InGaAs detection
MWIR Approximately 3–5 µm Cooled thermal imaging and high-temperature measurement
LWIR / thermal IR Approximately 8–14 µm PIR sensing, uncooled thermal cameras, and thermopiles
FIR Definition varies by field Frequently used informally for 8–14 µm PIR lenses

NASA Earth Science refers to 8–15 µm as thermal infrared because this region is useful for observing long-wave thermal energy emitted by the Earth. NASA’s remote-sensing classifications also include SWIR bands near 1.55–1.75 µm and 2.08–2.35 µm, illustrating why SWIR definitions may extend beyond the standard InGaAs range.
Source: NASA Science

For engineering specifications, it is therefore better to write:

  • 8–14 µm PIR Fresnel lens
  • LWIR thermal-imaging lens
  • 0.9–1.7 µm SWIR lens

rather than relying only on the term “FIR.”

At Fresnel Factory, the product terminology can be understood as follows:

  • Poly NIR series: Materials and lenses intended for selected near-infrared wavelengths such as 850, 905, 940, and 1,050 nm.
  • Poly FIR series: Polyethylene-based Fresnel lenses generally intended for human-detection applications near 8–14 µm.

Fresnel Factory provides separate categories for
PIR motion-detector Fresnel lenses
and
NIR and FIR optical components.
These categories should not be treated as interchangeable simply because both involve infrared wavelengths.

A material that performs well at 905 or 940 nm should not automatically be assumed to transmit efficiently at 1,310 or 1,550 nm. Spectral transmission must be verified across the wavelength range of the actual detector and illumination source.

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What Is the Main Difference Between SWIR and PIR Thermal Infrared?

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The most important difference is the origin of the radiation being detected.

Parameter SWIR PIR-Industry “FIR”
Full name Short-Wave Infrared Usually an informal name for LWIR or thermal IR
Typical operating range 0.9–1.7 µm 8–14 µm
Broader definitions May extend from approximately 0.7 to 2.5 µm FIR boundaries vary considerably by field
Main radiation source Reflected or transmitted sunlight, LED, or laser radiation Thermal radiation emitted by people, animals, and objects
Representative detector InGaAs, extended InGaAs, selected HgCdTe detectors Pyroelectric PIR, microbolometer, and thermopile
Typical applications Inspection, spectroscopy, moisture detection, wafer inspection, and laser imaging Motion detection, occupancy sensing, thermal imaging, and temperature measurement
Ordinary glass Some glass types can be used over selected SWIR bands Ordinary window glass is generally opaque at 8–14 µm
Common optical materials Selected optical glass, fused silica, silicon, and chalcogenide Polyethylene, germanium, ZnSe, ZnS, and chalcogenide
Active illumination Frequently used Not required for human thermal-radiation detection
Primary image information Reflectance, transmission, and absorption Surface temperature, emissivity, and thermal contrast

SWIR behaves more like visible-light imaging than conventional thermal imaging. Objects reflect, transmit, or absorb SWIR photons, and these differences create image contrast.

By contrast, PIR sensors and LWIR thermal cameras primarily detect energy emitted by objects because of their temperature.

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Which Wavelengths Are Commonly Used in SWIR Systems?

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A standard InGaAs detector generally covers approximately 0.9–1.7 µm. A representative Hamamatsu InGaAs photodiode specifies a cutoff wavelength of 1.7 µm and a typical peak-sensitivity wavelength of 1.55 µm.
Source: Hamamatsu Photonics

Wavelength Common Classification and Application
850 nm NIR illumination and sensing
905 nm Usually treated as NIR in LiDAR and ToF systems
940 nm NIR illumination, facial sensing, and 3D sensing
1,050–1,064 nm Boundary between NIR and SWIR terminology; industrial lasers
1,310 nm SWIR telecommunications and optical measurement
1,450 nm Strong water-absorption region
1,550 nm Telecommunications, eye-safer LiDAR, and SWIR imaging
Approximately 1,900 nm Strong moisture-sensitive spectral region
2.0–2.5 µm Spectroscopy and chemical identification

The classification boundaries overlap. For example, a 905 nm detector may technically fall within a broad SWIR definition, but most LiDAR engineers refer to 905 nm as NIR. For this reason, the wavelength itself should always be included in the product specification.

Extended-InGaAs detectors can reach longer wavelengths than conventional InGaAs devices. However, the detector material, optical material, coating, and illumination source must all be selected for the same spectral range.

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How Does a SWIR Camera Form an Image?

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Most SWIR cameras form images through a process similar to visible-light cameras:

  1. Sunlight, ambient radiation, a SWIR LED, or a laser illuminates the object.
  2. The object reflects, transmits, or absorbs different portions of the spectrum.
  3. The remaining radiation passes through the optical system.
  4. An InGaAs detector converts photons into electrical signals.
  5. The system produces a grayscale, multispectral, or hyperspectral image

Unlike a PIR sensor, a conventional SWIR camera does not normally detect a room-temperature person primarily from body heat. It usually detects sunlight, ambient nighttime radiation, or active illumination reflected from the person.

Hot metal, flames, furnaces, and molten materials can emit significant radiation in the SWIR band. However, that is a high-temperature application and should not be confused with ordinary human detection at room temperature.

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Why Do PIR Sensors Use Approximately 8–14 µm?

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The thermal-emission peaks of people and ordinary indoor objects therefore fall near 9–10 µm. This is one reason PIR sensors and uncooled thermal-imaging systems commonly operate in or near the 8–14 µm atmospheric window.

NASA describes 8–15 µm as a thermal-infrared region suitable for observing long-wave thermal radiation.
Source: NASA Science

The PIR sensor does not require an infrared LED or laser because the person is already the radiation source. This is the meaning of passive in Passive Infrared.

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How Is a PIR Sensor Different from a Thermal Camera?

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PIR sensors, microbolometer cameras, and thermopiles may all respond to thermal infrared, but they produce different types of information.

How Does a PIR Sensor Work?

A PIR sensor normally uses one or more pyroelectric elements. When the amount of infrared radiation reaching an element changes, the temperature and polarization of the pyroelectric material change, producing an electrical signal.

This expression means that a PIR sensor is primarily sensitive to a change in incident infrared flux, rather than a constant absolute temperature.

Murata explains that a pyroelectric sensor produces an output when the temperature of its pyroelectric ceramic changes. When the ceramic temperature remains stable, it does not continue to produce the same detection output.
Source: Murata Manufacturing

This explains several PIR characteristics:

  • A stationary person can become difficult to detect after the initial signal.
  • Movement across detection zones produces alternating signals.
  • Lens segments determine the direction and spatial distribution of the detection zones.
  • Amplifier bandwidth and digital detection algorithms strongly affect performance.

How Does a Microbolometer Work?

A microbolometer contains a two-dimensional array of pixels. Incident thermal radiation changes the temperature and electrical resistance of each pixel.

The camera can therefore produce a thermal image rather than a simple motion signal. With appropriate calibration, it may also estimate surface temperature.

Commercial LWIR camera lenses and modules are commonly designed for approximately 8–14 µm operation.
Source: Teledyne FLIR OEM

How Does a Thermopile Work?

A thermopile converts the temperature difference created by incident radiation into a thermoelectric voltage.

Thermopiles are commonly used in:

  • Non-contact thermometers
  • Occupancy and presence sensors
  • Low-resolution thermal arrays
  • Gas-analysis instruments
  • Appliance and industrial temperature sensing

Unlike a typical PIR element, a thermopile can respond to relatively steady thermal flux, although its response speed, sensitivity, and spatial resolution depend on the detector structure and signal processing.

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What Information Does SWIR Imaging Reveal?

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SWIR imaging shows differences in spectral reflectance, transmittance, and absorption.

Depending on the wavelength and material, SWIR can reveal:

  • Moisture-content variations
  • Bruising or defects in fruit and agricultural products
  • Contaminants in food-processing lines
  • Features beneath selected inks or coatings
  • Defects in solar cells
  • Structures through silicon wafers
  • Differences between polymers, textiles, minerals, and chemicals
  • Laser spots that are invisible to the human eye

NASA’s remote-sensing systems use SWIR bands to identify differences in leaf water content, minerals, soil characteristics, and other material properties.
Source: NASA Landsat

A SWIR image often resembles a monochrome visible-light image because it can include shadows, reflections, and illumination non-uniformity. However, objects with similar visible colors may appear very different when their SWIR absorption spectra differ.

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What Information Does an 8–14 µm Thermal System Reveal?

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An LWIR thermal image is affected by:

  • Surface temperature
  • Surface emissivity
  • Reflected thermal radiation
  • Thermal conductivity
  • Thermal capacity
  • Heat flow
  • Temperature changes over time
  • Thermal contrast between a target and its background

Two objects with the same visible color can appear very different in a thermal image when their temperatures or emissivities differ.

Conversely, objects with different visible colors may look similar in an LWIR image when their surface temperatures and emissivities are similar.

This distinction is important when selecting a detector. SWIR is usually selected to identify material or spectral differences, while LWIR is selected to identify thermal differences.

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Why Are SWIR and LWIR Lens Materials Different?

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Optical transparency is wavelength-dependent. A material that appears transparent to the human eye may be opaque at another infrared wavelength.

Which Materials Can Be Used for SWIR Optics?

For a conventional 0.9–1.7 µm system, candidate materials may include:

  • Selected optical glasses
  • Fused silica
  • Silicon
  • Sapphire
  • Chalcogenide glass
  • Selected SWIR-transmitting polymers
  • Crystalline infrared materials

SWIR optics generally use optical designs similar to visible-light systems, but the glass selection, anti-reflection coating, and chromatic correction must be optimized for the actual spectral range.

A visible-light lens may physically transmit part of the SWIR spectrum while still producing poor image quality because its focus shift, coating, aberration correction, and material absorption were not designed for that band.

Which Materials Can Be Used at 8–14 µm?

Typical LWIR optical materials include:

  • Germanium
  • ZnSe
  • ZnS
  • Chalcogenide glass
  • Selected infrared crystals
  • Polyethylene-based materials

Ordinary window and camera glass is unsuitable for most 8–14 µm applications. Special infrared-transmitting optical materials are therefore required.

High-resolution thermal cameras usually require precision germanium, chalcogenide, or other engineered infrared optics.

PIR motion detectors have different requirements. They normally prioritize:

  • Low manufacturing cost
  • Wide field of view
  • Detection-zone segmentation
  • Thin-wall construction
  • High-volume production
  • Outdoor durability
  • Suitable transmission near the human thermal-emission band

For these reasons, thin polyethylene-based Fresnel lenses are widely used in PIR motion sensors.

Fresnel Factory develops
wavelength-specific optical polymer materials,
including Poly NIR212, Poly FIR200, and Poly FIR25. The material must be selected according to the operating wavelength, required transmission, mechanical properties, environmental conditions, color, and molding process.

For a more detailed comparison of polyethylene compounds used in human-detection optics, see the
Guide to Material Selection for 8–14 µm FIR Lenses.
The guide discusses factors including infrared transmission, thickness attenuation, UV resistance, and compounded color materials.

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How Does SWIR Fresnel-Lens Design Differ from PIR Fresnel-Lens Design?

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The design objective changes significantly between the two applications.

What Is a SWIR Fresnel Lens Designed to Do?

A SWIR Fresnel lens may be developed for:

  • Concentrating radiation onto an InGaAs detector
  • Collimating a 1,310 or 1,550 nm source
  • Coupling light into a detector array
  • Spectrometer entrance optics
  • Structured illumination
  • Non-imaging collection
  • Compact low-resolution imaging

Important design parameters may include:

  • Spot size
  • Numerical aperture
  • Detector active area
  • Working distance
  • Focal length
  • Chromatic focal shift
  • Wavefront error
  • Modulation transfer function
  • Stray light
  • Fresnel reflection loss
  • Groove profile and surface roughness

Because SWIR wavelengths are relatively short, groove rounding, tool marks, surface roughness, and dimensional errors can introduce scattering and reduce concentration efficiency or image quality.

A Fresnel lens is not automatically suitable for every SWIR camera. A precision refractive lens may be more appropriate when high image resolution and low distortion are required.

What Is a PIR Fresnel Lens Designed to Do?

A PIR Fresnel lens is normally not intended to create a sharp image.

Its primary functions are to:

  • Divide a field of view into multiple detection zones
  • Direct each zone onto a pyroelectric element
  • Generate alternating signals as a target moves
  • Create near, middle, and far detection patterns
  • Establish wall-mount, ceiling-mount, or curtain patterns
  • Control blind spots and overlap
  • Match dual- or quad-element sensor geometry
  • Provide the required horizontal and vertical field of view

The PIR lens therefore behaves more like a field-mapping optic and spatial modulator than a conventional imaging lens.

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Can SWIR Be Used to See Heat?

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SWIR is infrared radiation, so it is not completely unrelated to temperature. However, it is generally unsuitable for observing thermal radiation from room-temperature people or objects.

A person near 310 K has a peak thermal-emission wavelength of approximately 9.35 µm. Thermal emission at 1.55 µm is extremely small by comparison.

A typical SWIR image of a person therefore shows:

  • Reflected sunlight
  • Reflected ambient nighttime radiation
  • Reflected SWIR LED radiation
  • Reflected 1,064 or 1,550 nm laser radiation

An 8–14 µm thermal camera or PIR sensor, by contrast, detects radiation emitted by the person and can operate without active illumination.

SWIR can be used for thermal measurement when the target is sufficiently hot, such as:

  • Molten metal
  • Furnaces
  • Flames
  • Hot glass
  • Semiconductor processes
  • High-temperature industrial components

In those cases, the target temperature shifts a meaningful portion of its thermal emission toward shorter wavelengths.

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When Should an Engineer Select SWIR?

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SWIR is appropriate when the system needs to:

  • Detect moisture-content differences
  • Inspect features beneath selected coatings or inks
  • Examine silicon wafers or photovoltaic cells
  • Detect a 1,310 or 1,550 nm laser
  • Perform food or agricultural sorting
  • Identify chemical or material differences
  • Build a SWIR spectrometer
  • Align an invisible laser
  • Receive a LiDAR signal
  • Improve imaging performance in selected haze, smoke, or low-light conditions
  • Use active illumination in approximately the 0.9–1.7 µm range

Performance through fog or smoke is not universal. It depends on wavelength, particle size, water content, atmospheric path length, and illumination power.

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When Should an Engineer Select PIR or LWIR?

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An 8–14 µm PIR or LWIR system is appropriate when the system needs to:

  • Detect human movement without active illumination
  • Detect occupancy at night
  • Produce a thermal image
  • Measure surface temperature
  • Inspect electrical overheating
  • Detect fires or hot spots
  • Control HVAC or building lighting
  • Detect animals
  • Perform perimeter surveillance
  • Identify thermal leakage or insulation defects

A PIR detector is normally preferred for low-cost motion detection.

A microbolometer is preferred when spatial thermal information or an image is required.

A thermopile is preferred when absolute or slowly changing radiation measurements are more important than motion-zone detection.

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How Can Polymer Fresnel Optics Be Used for Thermal Imaging?

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Polyethylene Fresnel optics can also be considered for compact, low-cost thermal-imaging systems where the required image resolution, field of view, detector format, and environmental conditions allow their use.

Fresnel Factory has developed an
HDPE lens module for 9–14 µm thermal-imaging sensors.
The prototype module uses HDPE and was developed with an 8 mm focal length and a 20° field of view for evaluation with a thermal-imaging sensor.

The company also published an evaluation using a
FLIR Boson 320 sensor with an HDPE Fresnel lens module.
This application demonstrates how molded polymer optics may be evaluated as an alternative to conventional precision infrared lens assemblies in selected compact thermal-camera designs.

Polymer Fresnel lenses are not a direct replacement for germanium or chalcogenide optics in every thermal camera. The acceptable solution depends on:

  • Detector resolution and pixel pitch
  • Required MTF and image quality
  • Focal length and field of view
  • Environmental temperature range
  • Lens thickness and transmission
  • Stray radiation and internal reflections
  • Mechanical packaging
  • Target manufacturing cost

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How Should a SWIR Detector Company Evaluate a Fresnel-Lens Supplier?

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A SWIR detector company should not evaluate a potential supplier only by asking whether it already manufactures “infrared lenses.”

The supplier should be able to define and verify:

  1. The exact wavelength or spectral band
  2. The detector material and active-area dimensions
  3. Whether the system is imaging or non-imaging
  4. The illumination source and beam characteristics
  5. The required field of view or numerical aperture
  6. The focal length and working distance
  7. The target spot size or energy distribution
  8. Material transmission across the complete operating band
  9. Surface-roughness and groove-profile requirements
  10. Environmental and production-volume requirements

Experience with 8–14 µm PIR optics does not automatically prove capability at 1,550 nm. Conversely, a material developed for 940 nm NIR sensing may not be suitable for a broadband 0.9–1.7 µm SWIR camera.

The wavelength-dependent refractive index, absorption, molding characteristics, coating requirements, detector architecture, and required image quality must all be reviewed.

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How Can Fresnel Factory Support SWIR and PIR Optical Development?

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Fresnel Factory’s established PIR capabilities include:

  • 8–14 µm polyethylene Fresnel-lens design
  • Human thermal-radiation collection
  • Wide-field detection-zone mapping
  • Dual- and quad-element pyroelectric sensor optics
  • Wall-mount, ceiling-mount, and curtain detection patterns
  • Injection-molded thermal-infrared optical components
  • Optical simulation and sensor performance testing

For a SWIR project, the development process should begin with the wavelength and system architecture rather than by reusing an existing PIR design.

Potential development support includes:

  • Material-transmission review for the target wavelength
  • Detector-coupling optical design
  • Fresnel concentrator design
  • Laser collimation or beam shaping
  • Detector-array coupling
  • Moldability and tolerance review
  • Prototype tooling
  • Injection-molding process development
  • Optical and system-level performance testing

Fresnel Factory’s
lens simulation and system design consultancy
supports the definition of the field of view, sensing distance, detector geometry, material, mechanical integration, and expected system performance. Optical design should begin before the external product design is finalized because the lens size, shape, and exposed optical area can affect both performance and industrial design.

Once the optical concept has been validated, the design can be transferred to
mold tooling, prototyping, and volume manufacturing.
This process includes converting the optical surface into a manufacturable mold design, reviewing post-molding shrinkage, selecting a suitable material, and controlling the mechanical tolerances between the lens, housing, and detector.

Manufactured optics and completed sensor assemblies can also be evaluated through
optical performance testing for infrared sensing devices.
The test service is intended for motion, presence, and LiDAR applications and can be used to compare simulation results with the performance of the manufactured device.

A Fresnel optical element can be effective when the objective is compact light collection, beam shaping, collimation, field mapping, or non-imaging concentration. For high-resolution SWIR imaging, the benefits and limitations of Fresnel optics should be evaluated against conventional multi-element refractive optics.

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Frequently Asked Questions

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Is SWIR the Same as Thermal Imaging?

No. SWIR normally forms an image from reflected or transmitted radiation, while thermal imaging normally detects radiation emitted by an object because of its temperature.

Is 905 nm Considered SWIR?

It falls within some broad SWIR definitions, but most LiDAR and sensing engineers classify 905 nm as NIR. Specifying the wavelength is more reliable than relying only on the band name.

Is 1,550 nm Considered SWIR?

Yes. A wavelength of 1,550 nm is within the conventional 0.9–1.7 µm SWIR range and is commonly detected using InGaAs devices.

Why Is an 8–14 µm PIR Lens Called an FIR Lens?

The term developed as an industry convention. More precise descriptions are “8–14 µm PIR lens,” “LWIR PIR lens,” or “thermal-infrared PIR lens.”

Can an Ordinary Glass Lens Be Used for SWIR?

Selected glass types can be used over portions of the SWIR spectrum. However, transmission, coating, focus shift, and aberration performance must be verified over the actual operating band.

Can Ordinary Glass Be Used for an 8–14 µm Thermal Camera?

Generally, no. Ordinary window and camera glass is largely opaque in this band, so infrared materials such as germanium, chalcogenide glass, or selected polymers are required.

Why Does a PIR Sensor Have Multiple Fresnel Segments?

Each segment maps a different region of space onto the pyroelectric elements. A moving target crosses these regions and creates the changing or alternating infrared signal required for motion detection.

Can One Fresnel-Lens Material Support Both 940 nm and 1,550 nm?

Possibly, but it should not be assumed. Transmission, refractive index, absorption, surface quality, and molding performance must be verified at both wavelengths.

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Conclusion

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SWIR and PIR thermal infrared should not be treated as interchangeable simply because both are called infrared.

A SWIR system near 0.9–1.7 µm generally observes reflected, transmitted, or actively illuminated radiation. A PIR or LWIR system near 8–14 µm detects thermal radiation emitted by people and objects.

This difference determines:

  • Detector technology
  • Illumination requirements
  • Optical materials
  • Lens geometry
  • Manufacturing tolerances
  • Test methods
  • The information contained in the resulting signal or image

When discussing a new infrared optical project, the most useful first question is therefore not:

“Is this an IR lens?”

It is:

“What is the exact operating wavelength, detector type, and optical function?”

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Discuss Your Infrared Optical Requirements

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Engineers can review Fresnel Factory’s standard components through the
Fresnel Factory supplier page on DigiKey.

For custom SWIR, NIR, PIR, thermopile, or thermal-imaging optics,
contact Fresnel Factory
with the following initial requirements:

  • Operating wavelength or spectral range
  • Detector model and active-area dimensions
  • Imaging or non-imaging application
  • Required field of view
  • Detection or working distance
  • Available lens dimensions
  • Target material and environmental conditions
  • Prototype and expected production quantities

Fresnel Factory operates from its head office in Suwon, South Korea, with a U.S. branch in Silicon Valley.

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About the Author

Ashton Kim is the CEO of Fresnel Factory Inc. His work focuses on Fresnel optical design, PIR and thermal-infrared sensor optics, injection-molded optical components, custom tooling, and sensor performance evaluation.

Related Articles

  • How to Design a 120° PIR Motion Sensor for Lighting Control
  • How PIR Fresnel Lenses Create Detection Zones
  • HDPE vs. Silicon vs. Germanium for Infrared Optical Systems

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How to Design a 120° PIR Motion Sensor for Lighting Control: Why Mechanical Design Matters as Much as Optical Performance

Last Updated: July 16, 2026
Author: Ashton Kim, CEO, Fresnel Factory Inc.
Target Readers: Hardware Engineers and R&D Managers
Application: PIR-Based Lighting Automation

Quick Answer

Achieving a reliable 120° horizontal detection area with a PIR sensor is difficult when the Fresnel lens must remain flat and flush with the product surface. In this lighting-control project, the central target was approximately 6 m, while the outer detection zones were expected to retain at least 50% of the central performance.

  1. A nominal 120° lens FoV is not the same as a guaranteed 120° human-detection area.
  2. The PIR sensor, lens, PCB position, focal distance, and enclosure must be designed as one optical system.
  3. Increasing the sensor-to-lens distance from approximately 8 mm toward 9.5 mm can provide more optical design flexibility.
  4. A lens width of approximately 40 mm may support a wide horizontal detection pattern, but the available vertical area must also be reviewed.
  5. Adding a second PIR sensor does not automatically create a significantly wider FoV unless its position or installation angle is changed.
  6. The Fresnel lens supplier should participate before the mechanical design and PCB position are frozen.

What Was the Customer Trying to Develop?

A global building-automation company approached Fresnel Factory during the early development stage of a new PIR-based lighting-control product. The device was intended to detect human movement across a wide area and use that information to control lighting automatically.

The customer had already selected a compact, low-profile SMD PIR sensor from Murata. The baseline concept used one PIR sensor mounted on a PCB parallel to the wall. The Fresnel lens also needed to remain flat and aligned with the exterior surface of the product.

The primary development targets were:

  • Approximately 120° horizontal field of view
  • Approximately 6 m detection range in the central zone
  • At least 50% of the central performance in the outer zones
  • A flat Fresnel lens flush with the product surface
  • A clean exterior without excessive molding or shrink marks
  • One PIR sensor as the baseline architecture
  • Approximately 30° vertical FoV under review
  • Target production by the end of 2027

The main question was not simply whether the selected sensor could detect a person at 6 m. The more difficult question was whether the system could create a reliable 120° horizontal detection area while remaining within the mechanical and cosmetic limitations of the product.

Why Is a 120° FoV Difficult With a Flat PIR Fresnel Lens?

A PIR Fresnel lens divides the monitored space into multiple optical zones and directs far-infrared energy from a moving person toward the pyroelectric sensing elements. The geometry of these zones depends on the sensor element arrangement, focal distance, lens dimensions, Fresnel segment geometry, and the position of the sensor relative to the lens.

Wide-angle detection becomes more difficult when the optical surface must remain completely flat. A curved or angled lens surface can provide more favorable geometry for collecting infrared energy from the far-left and far-right detection zones. A flat lens provides less freedom for redirecting these steep peripheral rays toward a small PIR sensing element.

To compensate for this limitation, the optical designer may need to use a larger lens area, increase the focal distance, adjust the sensor position, or use more aggressive Fresnel segment geometry. Each option affects other parts of the product.

  • A larger lens requires more exterior and internal space.
  • A longer focal distance increases the required housing depth.
  • A tilted sensor may require a separate PCB or mechanical bracket.
  • Aggressive segment geometry can make injection molding and cosmetic control more difficult.
  • A wider horizontal FoV may reduce the optical area available for vertical coverage.

For this reason, a 120° requirement should not be treated as a lens specification alone. It is a system-level requirement involving the PIR sensor, optics, electronics, mechanical structure, and performance-test criteria.

How Should a 120° PIR Detection Requirement Be Defined?

PIR field of view can be defined differently by different sensor and lens suppliers. A nominal optical angle, a simulated detection zone, and a guaranteed human-detection area are not necessarily the same.

For this project, the 120° target was interpreted as an effective horizontal detection area. The central zone was expected to detect a person at approximately 6 m. The outer zones did not need to provide exactly the same distance, but they were expected to retain at least 50% of the central detection performance.

This is more useful than stating only “120° FoV,” because it defines how the product should perform across the monitored area.

A practical PIR requirement should specify:

  • The guaranteed horizontal detection angle
  • The guaranteed vertical detection angle
  • The central detection distance
  • The minimum peripheral detection distance or performance ratio
  • The installation height
  • The direction and speed of human movement
  • The target size and clothing conditions
  • The ambient and target temperature difference
  • The PIR signal threshold and pass/fail criteria

Without a common test definition, one supplier may describe a lens as 110°, while another may describe a similar detection pattern as 120°. Fresnel Factory therefore recommends reviewing the actual detection map rather than comparing only the FoV number printed on a datasheet.

What Design Changes Were Evaluated During the Consultation?

1. Increasing the Sensor-to-Lens Distance

The preliminary mechanical drawing provided approximately 8 mm between the PIR element and the lens surface. Increasing this distance toward approximately 9.5 mm was discussed.

A longer focal distance can provide more design freedom when assigning the outer Fresnel zones. It does not guarantee 120° performance by itself, but it can make the target more feasible within a flat-lens structure.

2. Using the Available Horizontal Lens Area

The proposed lens width was approximately 40 mm. Fresnel Factory had experience with a similar wide-angle design using an optical surface of approximately 37 mm and a focal distance of about 9.5 mm.

This suggested that the available horizontal width could be sufficient for continued development, provided that the sensor position and focal distance were adjusted appropriately.

3. Increasing the Vertical Optical Area

The preliminary vertical lens area was only about 7 mm. If the customer retains an approximately 30° vertical FoV requirement, the vertical optical area may need to be increased.

A wide horizontal FoV and a wide vertical FoV compete for the limited lens surface. The final window dimensions should therefore be determined after both requirements are confirmed.

4. Evaluating Sensor Tilt

The baseline design positioned the PIR sensor parallel to the wall without horizontal or vertical tilt. A controlled sensor angle could improve coverage in a selected direction, but it would require mechanical or PCB changes.

Because the product was still in an early design phase, the customer agreed to review whether the internal structure could accommodate these changes.

5. Evaluating a Dual-Sensor Architecture

A second PIR sensor was considered as an optional way to increase coverage. However, placing two sensors on the same plane and at the same angle does not automatically double the field of view.

In the discussed geometry, the increase could be limited to approximately 10° unless the sensors were separated, tilted, or assigned different optical zones. A dual-sensor design must therefore be evaluated together with the PCB layout, signal-processing method, cost target, and enclosure space.

6. Using the Sensitivity of the Selected PIR Sensor

Based on Fresnel Factory’s previous design experience, the selected Murata PIR sensor was expected to provide strong signal sensitivity compared with several conventional alternatives.

This made the 6 m central detection target relatively manageable. The more significant design challenge remained the wide peripheral coverage created by the flat optical surface.

How Did the Engineering Direction Change After the Consultation?

Design Item Initial Development Target Engineering Direction After Consultation
Horizontal FoV 120° Retain 120° as the effective detection-zone target
Central Detection Range Approximately 6 m Maintain approximately 6 m
Peripheral Detection Not fully defined Define as at least 50% of central performance
Sensor-to-Lens Distance Approximately 8 mm Evaluate an increase toward approximately 9.5 mm
Lens Width Approximately 40 mm Retain and optimize the available width
Lens Height Approximately 7 mm Increase if an approximately 30° vertical FoV is mandatory
Lens Exterior Flat and flush Retain while recognizing wide-angle optical limitations
Number of PIR Sensors One sensor One sensor as baseline; two sensors as an optional study
Sensor Installation Angle Parallel to the wall Evaluate horizontal or vertical tilt if mechanically possible
Cosmetic Requirement Clean exterior surface Balance optical geometry with molding and shrink-mark control
Target Production End of 2027 Allow sufficient time for simulation, tooling, testing, and iteration

Why Should the Fresnel Lens Supplier Join the Project Early?

In many PIR projects, the enclosure, PCB, and optical window are designed first, and the lens supplier is contacted only after the mechanical structure has been frozen. This sequence creates unnecessary design risk.

The following parameters are directly connected:

  • PIR sensor element size and arrangement
  • Sensor package height
  • PCB position and installation angle
  • Sensor-to-lens distance
  • Lens width and height
  • Horizontal and vertical detection zones
  • Housing depth and exterior curvature
  • Lens material and injection-molding conditions
  • Cosmetic surface requirements

If the PCB position is fixed too close to the lens, the optical designer may not have enough focal distance to create the required peripheral zones. If the optical window is too narrow vertically, the target vertical FoV may not be achievable. If the enclosure must remain completely flat, a wider lens area or different sensor position may be necessary.

Early collaboration allows these trade-offs to be evaluated before tooling begins. In this project, the customer’s mechanical team could still review the additional 1.5 mm of sensor-to-lens distance, lens-window height, and possible sensor tilt before the internal structure was finalized.

What Information Should Engineers Prepare for a Custom PIR Lens Project?

Providing the following information allows an optical supplier to evaluate feasibility more accurately:

  1. PIR sensor manufacturer and exact part number
  2. Pyroelectric element dimensions and arrangement
  3. Required horizontal and vertical FoV
  4. Central and peripheral detection-distance targets
  5. Product installation height and orientation
  6. Expected human movement direction
  7. Available sensor-to-lens distance
  8. Maximum optical-window width and height
  9. Flat, curved, tilted, or recessed exterior requirements
  10. PCB position and allowable sensor angle
  11. Cosmetic and injection-molding restrictions
  12. Target development schedule and production volume

A 3D mechanical drawing is useful, but it should be considered a starting point rather than a fixed constraint during the first optical feasibility review.

How Can Fresnel Factory Support a New PIR Product?

Fresnel Factory supports PIR projects from initial feasibility review through optical design, tooling, manufacturing, and performance verification.

  • Review of PIR sensor geometry and package dimensions
  • Recommended sensor-to-lens distance
  • Horizontal and vertical detection-zone design
  • Custom Fresnel segment layout
  • Mechanical integration guidance
  • Evaluation of single- and dual-sensor architectures
  • Optical simulation and design iteration
  • Prototype tooling and injection molding
  • PIR signal and detection-pattern testing
  • Collaboration with customer mechanical and electronics teams

The objective is not simply to manufacture a lens that fits an existing opening. It is to define a sensor, lens, and mechanical arrangement that can be tested against a measurable detection requirement.

What Was the Main Engineering Lesson From This Project?

The primary challenge was not whether the selected PIR sensor could detect a person at 6 m. The greater challenge was achieving a reliable 120° horizontal detection area while keeping the lens flat, preserving a clean exterior, and fitting the optical system within the available mechanical space.

The practical solution was therefore not a lens-only modification. It required coordinated optimization of the lens area, focal distance, sensor position, vertical coverage, PCB structure, and enclosure design.

For hardware engineers and R&D managers beginning a PIR project, the most important step is to involve the optical supplier before the mechanical design is frozen. A few millimeters of additional focal distance or lens-window area during the concept stage can prevent major performance compromises and costly redesign later.

Frequently Asked Questions

Can a flat PIR Fresnel lens achieve a 120° field of view?

It may be possible, but feasibility depends on the PIR element size, focal distance, lens dimensions, required detection range, and test criteria. A flat surface makes peripheral-zone design more difficult than a curved or angled lens.

Does a 120° lens FoV guarantee 6 m detection across the entire angle?

No. A nominal lens FoV does not guarantee equal detection distance at every angle. The central and peripheral detection targets should be defined separately.

What sensor-to-lens distance is required for a wide-angle PIR design?

There is no universal distance. In this project, increasing the distance from approximately 8 mm toward 9.5 mm was considered to provide more optical design flexibility.

Does using two PIR sensors double the field of view?

No. If two sensors are installed on the same plane and at the same angle, the improvement may be limited. Their positions, angles, optical zones, and signal-processing method must be designed together.

Why can two suppliers state different FoV values for similar PIR lenses?

Suppliers may use different signal thresholds, walking paths, target conditions, and definitions of guaranteed versus non-guaranteed detection. Detection maps and test conditions should be compared instead of the angle alone.

Why does the vertical size of the PIR lens matter?

The vertical lens area determines how much optical space is available for vertical detection zones. A very narrow lens may restrict the achievable vertical FoV even when sufficient horizontal width is available.

When should a Fresnel lens supplier become involved?

The supplier should be involved before the PCB position, housing depth, optical-window dimensions, and sensor installation angle are finalized.

Start a PIR Optical Feasibility Review

To evaluate a new PIR project, prepare the sensor part number, target detection map, installation height, PCB position, lens-window dimensions, and preliminary 3D mechanical data.

Request a custom PIR lens feasibility review from Fresnel Factory

Engineers looking for standard Fresnel Factory components can also review available products through
Fresnel Factory’s DigiKey Supplier Center.


About the Author
Ashton Kim is the CEO of Fresnel Factory Inc. His work focuses on Fresnel optical design, PIR and TMOS sensor optics, infrared lens manufacturing, injection molding, and custom sensor-system development. He also work for IEC building international standards for sensors.

Technical Note: The dimensions and performance targets in this article describe an engineering consultation at the concept-development stage. Final performance must be verified through optical simulation, prototype production, and physical detection testing.