Custom composite beam light assembly

A lighting assembly for a luminaire, comprising:

• a circuit board;
• light sources arranged on a first surface of the circuit board;
• a heat sink coupled to a second surface of the circuit board, the second surface being opposite the first surface;
• at least one solid integrated optical array coupled to the first surface of the circuit board, wherein the at least one solid integrated optical array includes a base with solid optical lenses fixed thereto, each solid optical lens disposed over a corresponding one of the light sources, and wherein each solid optical lens includes:
• a light guiding body defining a total internal reflection lens;
• and
• an outer light directing surface, each solid optical lens adapted to pass a light beam in a predefined direction to form a beam pattern, wherein each solid optical lens is configured to maintain a base beam size of light passing therethrough, the base beam size being less than eleven degrees;
• and
• a bezel disposed adjacent to the at least one solid integrated optical array and sealingly coupled to the heat sink.

A method of designing a luminaire, comprising:

• determining a light output pattern and distribution of light at a target area;
• selecting solid optical lenses to form an optical array of rows of the solid optical lenses;
• rotating each solid optical lens about an aiming axis to define a direction of directed light in conjunction with redirection of the directed light by a molded light directing surface to form a beam pattern of the optical array, each solid optical lens being a narrow beam optical lens configured to define a base beam size of less than eleven degrees for the directed light passing therethrough;
• molding the solid optical lenses into the optical array;
• selecting and positioning multiple optical arrays over light sources on a circuit board to form a light assembly defining a composite light beam;
• and
• selecting multiple light assemblies to form the luminaire defining the light output pattern and the distribution of light at the target area.