What limits the maximum sensor size a lens can cover without vignetting?

Asked 2/17/2013

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If a larger sensor captures a wider field of view from the same focal length, what determines how large that sensor can be before the lens starts showing dark corners or a black border? Is the limit set by the rear element, the front element, the lens barrel, or something else?

Originally by Photography Stack Exchange contributor. Source · Licensed CC BY-SA 4.0

Photography Stack Exchange contributor

13y ago

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It depends on the lens design, a wide angle retrofocus lens is mainly limited by the front element size, the lens barrel places a hard limit on the range of angles that can see the entrance pupil. As an example of this mounting a filter on an ultrwide can reduce the size of the image circle. This is why separate designs exist for APS-c DSLRs, but mostly for wide lenses, as the front element can be made smaller, saving weight.

With symmetric designs like most 50mm lenses the determining factor is sharpness - it's easy to make the image circle bigger but corner sharpness drops off very rapidly limiting the sensor you can practically use. Most 50mm ish lenses designed for APS-C mirrorless cameras would cover full frame but be very soft in the corners. The front element of a telephoto lens only has to be big enough to see the entrance pupil from a narrow range of angles so the image circle could be made larger but with a decrease in corner sharpness.

Finally sometimes the image circle is intentionally limited by mechanical vignetting in the rear of the lens. There's no point in casting a larger circle than you plan to use as the wasted light can reflect off surfaces inside the camera and cause flare. This is onl y really an issue with wide angle lenses as you could compose a shot with the sun out of frame (according to the viewfinder) and still have it shining through the lens.

Originally by user1375. Source · Licensed CC BY-SA 4.0

user1375

13y ago

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The key limit is the lens’s image circle: the circular area of usable light the lens projects onto the sensor. A sensor larger than that circle will show dark corners or a black border.

What sets the image circle depends on the lens design. In wide-angle retrofocus lenses, the front element size and the lens barrel can physically limit the range of rays that reach the sensor, so they strongly affect coverage. That’s why very wide lenses are often format-specific, and why adding a filter to some ultra-wides can increase vignetting.

With more symmetric designs, such as many normal lenses around 50mm, the lens may project light over a larger area than the intended format, but image quality usually falls off quickly toward the edges. So the practical limit is often not total coverage, but poor corner sharpness and other edge degradation.

So it isn’t just one element. The maximum usable sensor size is determined by the overall optical design and mechanical constraints, especially the image circle and how good the image remains near its edge.

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