Originally Posted by TerminatorX5

so, you guys take into the account that the lens in front of the light bulb is a magnifying lens that has a specific focal point that is projected on the front surface, and the cut-off is "sharp" only at the point of focus, at a specific distance from the lens?

and that the curvature of the optical lens breaks the produced light into the spectrum components of the light that are highly visible at the edge of the beam pattern, and thus producing the bluish-purplish tint at the cut-off line that actually blurs the line...

Think of an overhead projector (or any projector for that matter of fact) - the lines at the edges of a picture (as well as the picture itself) will be blurry if the distance to the projected surface is different from the focal point of the lens.

have you calculated the focal point of the headlight projector lens? are you evaluating the cut-off line at a pre-measured distance?

I am not an optical engineer but i suspect, you are chasing a unicorn in your pursuit of perfection... {wink-wink}