Square sensors impossible?

It does not matter what shape your sensor is, people can crop to whatever shape they require. look at the photo's on this site displayed by many different photographers , there are many different shapes , but few are square, cropping from a square sensor every time would waste a lot of pixels, for the majority of photographers.

https://www.ephotozine.com/gallery/id/57980601
 
Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.

Let's say that you want to record 36mm x 36mm images. A sensor with these dimensions would have a diagonal of almost 51mm. That sensor certainly "spills beyond" the 43mm full-frame image circle – and so full-frame lenses will not cover it with good images. Your 36mm x 36mm square captures will suffer from dark corners ("significant vignetting").

A ~30mm square will fit into the FF image circle, but even that square might be 6mm too tall for lenses with baffling.
 
If you are designing a new camera mount, you can make the sensor whatever size you want, and design the lenses for that size.

If you are using existing "full frame" DSLR lenses you may be limited to the existing 24mm by 36mm sensor size, as some lenses have internal baffles, and the "image circle" is not really a circle when you take vignetting into account.

If you are using existing "full frame" DSLR lenses, and you want to build a DSLR, you are pretty much limited to the existing 24mm by 36mm sensor size by the requirements of the mirror. If you are building a mirrorless camera, then the mirror isn't an issue, but you may as well use a shorter registration distance. That gets us back to designing new lenses that won't have internal baffles.

In terms of which aspect ratio is the "best", that's an esthetic issue. From an engineering and scientific standpoint, the best sensor aspect ratio is the one that matches your final image. The best ratio for your final image is an artistic question, not a technical one.

Thus you are going to get different answers based on the artistic tastes of the photographer, whether they prefer mirrorless or DSLR, and whether they want to use existing lenses, or are willing to build new lenses, that are almost like existing lenses, but with no 2:3 internal baffles.
 
Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors? They wouldn't behave differently WRT vignetting than rectangular ones. Unless you override the default aspect ratios and really want the whole thing with black corners and all. My idea is that the square version should accommodate the present formats thus be at least long side squared. Even I would admit that nobody wants a 30x30 sensor for FF.
Let's say that you want to record 36mm x 36mm images.
But I don't. I want to record 30x30 in this example. So I can use my old lenses.
A sensor with these dimensions would have a diagonal of almost 51mm. That sensor certainly "spills beyond" the 43mm full-frame image circle – and so full-frame lenses will not cover it with good images. Your 36mm x 36mm square captures will suffer from dark corners ("significant vignetting").

A ~30mm square will fit into the FF image circle, but even that square might be 6mm too tall for lenses with baffling.
True that some lenses have baffles. For this discussion I consider that a side issue. It's more about the principle. A more serious problem is that some mounts (such as Sony (as demonstrated by one poster) have the contacts intruding into the IC so no way they could use a square sensor.
 
LOL, you just disproved your own point with that image.
How? My point is that the sensor should be enlarged to 6000x6000 in which case there's no penalty in terms of resolution in any aspect ratio. Photonut's post was rather confusing so might have misunderstood. Particularly the part about vignetting.
 
Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors? They wouldn't behave differently WRT vignetting than rectangular ones. Unless you override the default aspect ratios and really want the whole thing with black corners and all. My idea is that the square version should accommodate the present formats thus be at least long side squared.
A square sensor that is covered by the current image circle of a FF lens would be just over 30mm x 30mm, not 36mm x 36mm. To be covered by an image circle, the diagonal of the sensor must be no greater than the diameter of the image circle. The diagonal of a 36mm x 24mm sensor is not quite 44mm, so we assume the image circle diameter to be about 44mm. A square sensor with the same diagonal is just over 30mm x 30mm. So if you made a 36mm x 36mm sensor, which has a diagonal of about 51mm, the corners of the sensor would extend 3,5mm beyond the outside of the image circle, and this wouls give you strong vignetting.
Even I would admit that nobody wants a 30x30 sensor for FF.
Well that's about the largest square sensor a current FF lens will reliably cover.
 
LOL, you just disproved your own point with that image.
How? My point is that the sensor should be enlarged to 6000x6000 in which case there's no penalty in terms of resolution in any aspect ratio. Photonut's post was rather confusing so might have misunderstood. Particularly the part about vignetting.
But there are penalties in terms of performance, contrast, veiling flare, complexity and cost.

The camera needs to be designed with the assumption that you might use all of the pixels on the sensor. Increasing the pixel count requires faster hardware, or slower overall performance.

Sensors have a mirror-like finish. Some of the light that hits the sensor reflects into the camera and introduces veiling flare. Obviously, we need to let light fall onto the pixels we want in our final image. However, anytime we are not using pixels, we have a mirror-like surface, and no advantage. This could be addressed by having an adjustable matte black mask that would move to cover the parts of the sensor not being used.

As a general rule, the cost of the sensor increases with sensor size. Anytime the sensor is larger than what you need, you are spending more for that sensor.

Also, if you are routinely cropping the sensor, then your lenses have a larger than necessary image circle. This means the lens may be more expensive, heavier, or more flare prone than necessary.

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Has anyone actually done a study to determine what percentage of images are presented in particular aspect ratios? If we had that information, we could determine what aspect ratio would be the best fit for typical images.
 
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Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors? They wouldn't behave differently WRT vignetting than rectangular ones. Unless you override the default aspect ratios and really want the whole thing with black corners and all. My idea is that the square version should accommodate the present formats thus be at least long side squared.
A square sensor that is covered by the current image circle of a FF lens would be just over 30mm x 30mm, not 36mm x 36mm. To be covered by an image circle, the diagonal of the sensor must be no greater than the diameter of the image circle. The diagonal of a 36mm x 24mm sensor is not quite 44mm, so we assume the image circle diameter to be about 44mm. A square sensor with the same diagonal is just over 30mm x 30mm. So if you made a 36mm x 36mm sensor, which has a diagonal of about 51mm, the corners of the sensor would extend 3,5mm beyond the outside of the image circle, and this wouls give you strong vignetting.
Even I would admit that nobody wants a 30x30 sensor for FF.
Well that's about the largest square sensor a current FF lens will reliably cover.
Ok I guess I need to spell it out once more: the only square sensor that makes any sense is one that allows present aspect ratios without compromising resolution in addition to the benefits for more square aspects, thus must be at least 36x36 for FF. Suitable sizes for APS and M43 respectively would be 24x24 and 18x18 (rounded upwards). The parts of the square that fall outside the IC are discarded by default. It's called an oversized sensor. I believe Panasonic has an LX something with one though it's not square.
 
LOL, you just disproved your own point with that image.
How? My point is that the sensor should be enlarged to 6000x6000 in which case there's no penalty in terms of resolution in any aspect ratio. Photonut's post was rather confusing so might have misunderstood. Particularly the part about vignetting.
But there are penalties in terms of performance, contrast, veiling flare, complexity and cost.

The camera needs to be designed with the assumption that you might use all of the pixels on the sensor. Increasing the pixel count requires faster hardware, or slower overall performance.

Sensors have a mirror-like finish. Some of the light that hits the sensor reflects into the camera and introduces veiling flare. Obviously, we need to let light fall onto the pixels we want in our final image. However, anytime we are not using pixels, we have a mirror-like surface, and no advantage. This could be addressed by having an adjustable matte black mask that would move to cover the parts of the sensor not being used.
I use a m4/3 camera that can be set to sq format, 16x8, 2x3 or 3x4. When you frame the shot in the viewfinder, the viewfinder shows only that format, but the camera still records the whole sensor image of 4x3, it is presented for review as the whole 4x3 but framed with a white line depicting the chosen format. You can revert back to to 4x3 in PP, no need for a mask.
As a general rule, the cost of the sensor increases with sensor size. Anytime the sensor is larger than what you need, you are spending more for that sensor.

====

Has anyone actually done a study to determine what percentage of images are presented in particular aspect ratios? If we had that information, we could determine what aspect ratio would be the best fit for typical images.
 
...But there are penalties in terms of performance, contrast, veiling flare, complexity and cost.

The camera needs to be designed with the assumption that you might use all of the pixels on the sensor. Increasing the pixel count requires faster hardware, or slower overall performance.

Sensors have a mirror-like finish. Some of the light that hits the sensor reflects into the camera and introduces veiling flare. Obviously, we need to let light fall onto the pixels we want in our final image. However, anytime we are not using pixels, we have a mirror-like surface, and no advantage. This could be addressed by having an adjustable matte black mask that would move to cover the parts of the sensor not being used.
I use a m4/3 camera that can be set to sq format, 16x8, 2x3 or 3x4. When you frame the shot in the viewfinder, the viewfinder shows only that format, but the camera still records the whole sensor image of 4x3, it is presented for review as the whole 4x3 but framed with a white line depicting the chosen format. You can revert back to to 4x3 in PP, no need for a mask.
The issue is that if you were shooting square, and you masked the sensor to square, the camera would be a little less flare prone.

It's not a big difference, but then none of the things being discussed here are big differences.
 
LOL, you just disproved your own point with that image.
How? My point is that the sensor should be enlarged to 6000x6000 in which case there's no penalty in terms of resolution in any aspect ratio. Photonut's post was rather confusing so might have misunderstood. Particularly the part about vignetting.
But there are penalties in terms of performance, contrast, veiling flare, complexity and cost.

The camera needs to be designed with the assumption that you might use all of the pixels on the sensor. Increasing the pixel count requires faster hardware, or slower overall performance.
Yes but APS cameras are no more expensive than M43 cameras so can hardly be a problem. FF may be different as the price curve turns upward just beyond that. Which is why I advocate square sensors for M43 and APS, not FF. This thread just got off with FF and for many of us it's still some sort of reference so here we are. As a theoretical example it's as good as any other. It's a scalable thing, applicable to anything from 1/2.5" to ME.
Sensors have a mirror-like finish. Some of the light that hits the sensor reflects into the camera and introduces veiling flare. Obviously, we need to let light fall onto the pixels we want in our final image. However, anytime we are not using pixels, we have a mirror-like surface, and no advantage. This could be addressed by having an adjustable matte black mask that would move to cover the parts of the sensor not being used.
That's a neat idea. However I think you exaggerate the issue. Canon lenses may have baffles but haven't seen any on my M43 lenses. Haven't noticed any particular problems with flare though a scientific study could show an advantage for Canon. Of course the same goes for hoods. I use mainly round ones because of stepup rings and sometimes it's even what the lens maker provides. Anyway, zooms render hoods rather ineffective much of the time anyway.
As a general rule, the cost of the sensor increases with sensor size. Anytime the sensor is larger than what you need, you are spending more for that sensor.
That is true in theory but again: compare M43 and APS. Can't see much of a problem. And consider this: a square sensor lets you utilize more of the lens' image circle every time you go from 3:2 or 4:3 toward squared ratios. And you gain AoV. So how I see it is that the advantages would heavily outweigh the costs.
Has anyone actually done a study to determine what percentage of images are presented in particular aspect ratios? If we had that information, we could determine what aspect ratio would be the best fit for typical images.
Shouldn't be too hard. On Instagram square is still popular in spite of them allowing rectangular nowadays. So actually the real surprise is that phones don't get square sensors either. Weird.
 
Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors? They wouldn't behave differently WRT vignetting than rectangular ones. Unless you override the default aspect ratios and really want the whole thing with black corners and all. My idea is that the square version should accommodate the present formats thus be at least long side squared.
A square sensor that is covered by the current image circle of a FF lens would be just over 30mm x 30mm, not 36mm x 36mm. To be covered by an image circle, the diagonal of the sensor must be no greater than the diameter of the image circle. The diagonal of a 36mm x 24mm sensor is not quite 44mm, so we assume the image circle diameter to be about 44mm. A square sensor with the same diagonal is just over 30mm x 30mm. So if you made a 36mm x 36mm sensor, which has a diagonal of about 51mm, the corners of the sensor would extend 3,5mm beyond the outside of the image circle, and this wouls give you strong vignetting.
Even I would admit that nobody wants a 30x30 sensor for FF.
Well that's about the largest square sensor a current FF lens will reliably cover.
Ok I guess I need to spell it out once more: the only square sensor that makes any sense is one that allows present aspect ratios without compromising resolution in addition to the benefits for more square aspects, thus must be at least 36x36 for FF. Suitable sizes for APS and M43 respectively would be 24x24 and 18x18 (rounded upwards). The parts of the square that fall outside the IC are discarded by default. It's called an oversized sensor. I believe Panasonic has an LX something with one though it's not square.
So you want to put something like a 36MP 36mm x 36mm oversize sensor into a camera and use it to take 26MP square pictures, 25MP 4:3 pictures, 24MP 3:2 pictures and 22.5MP 16:9 pictures, using current FF lenses.

I suppose you could do it with mirrorless, but not dSLRs, and only for lenses that had no baffles.
 
Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors? They wouldn't behave differently WRT vignetting than rectangular ones. Unless you override the default aspect ratios and really want the whole thing with black corners and all. My idea is that the square version should accommodate the present formats thus be at least long side squared.
A square sensor that is covered by the current image circle of a FF lens would be just over 30mm x 30mm, not 36mm x 36mm. To be covered by an image circle, the diagonal of the sensor must be no greater than the diameter of the image circle. The diagonal of a 36mm x 24mm sensor is not quite 44mm, so we assume the image circle diameter to be about 44mm. A square sensor with the same diagonal is just over 30mm x 30mm. So if you made a 36mm x 36mm sensor, which has a diagonal of about 51mm, the corners of the sensor would extend 3,5mm beyond the outside of the image circle, and this wouls give you strong vignetting.
Even I would admit that nobody wants a 30x30 sensor for FF.
Well that's about the largest square sensor a current FF lens will reliably cover.
Ok I guess I need to spell it out once more: the only square sensor that makes any sense is one that allows present aspect ratios without compromising resolution in addition to the benefits for more square aspects, thus must be at least 36x36 for FF. Suitable sizes for APS and M43 respectively would be 24x24 and 18x18 (rounded upwards). The parts of the square that fall outside the IC are discarded by default. It's called an oversized sensor. I believe Panasonic has an LX something with one though it's not square.
So you want to put something like a 36MP 36mm x 36mm oversize sensor into a camera and use it to take 26MP square pictures, 25MP 4:3 pictures, 24MP 3:2 pictures and 22.5MP 16:9 pictures, using current FF lenses.
Precisely, except scaled down to M43 as that's what I have and can't afford a system upgrade.
I suppose you could do it with mirrorless, but not dSLRs, and only for lenses that had no baffles.
Those are the restrictions + some mounts block the "view" with the contacts. Not M43 or Pentax as far as I can see.
 
So you want to put something like a 36MP 36mm x 36mm oversize sensor into a camera and use it to take 26MP square pictures, 25MP 4:3 pictures, 24MP 3:2 pictures and 22.5MP 16:9 pictures, using current FF lenses.
Precisely, except scaled down to M43 as that's what I have and can't afford a system upgrade.
The oversized sensor would probably cost more than a system upgrade. Certainly adding a NEX6 and a few adapters to give me APSC cost less than £200, even FF mirrorless systems can be had for under £500.
I suppose you could do it with mirrorless, but not dSLRs, and only for lenses that had no baffles.
Those are the restrictions + some mounts block the "view" with the contacts. Not M43 or Pentax as far as I can see.
Looking at a MFT lens you might thing that but I've just had a quick look at one of my MFT bodies. The contacts would be in the way of stretching the sensor to be the same height as it's width. There's very little space between the lower corners of the sensor & the end contacts.

If your body doesn't have those contacts (with most lenses loosing aperture control & any ability to focus - many MFT lenses are focus by wire & don't work without the power/communications it's not just going manual) the lenses will typically cover enough. Several of mine cover APSC but it's only the manual focus models that are worth considering. Using the zoom control for focusing is not practical!

The Pentax mount MIGHT be OK but the internal contacts for electronic AF (the old power zoom contacts) are pretty close too.
 
That's a neat idea. However I think you exaggerate the issue. Canon lenses may have baffles but haven't seen any on my M43 lenses. Haven't noticed any particular problems with flare though a scientific study could show an advantage for Canon. Of course the same goes for hoods. I use mainly round ones because of stepup rings and sometimes it's even what the lens maker provides. Anyway, zooms render hoods rather ineffective much of the time anyway.
It becomes more of an issue when there are light sources in the part of the field of view that will be cropped out. You don't want the image of the light source bouncing off the mirror-like sensor if you aren't going to have it in your final image.

It's not usually a big deal, but then cropping a 2:3 sensor to square isn't usually a problem. All of these issues are rather minor.
As a general rule, the cost of the sensor increases with sensor size. Anytime the sensor is larger than what you need, you are spending more for that sensor.
That is true in theory but again: compare M43 and APS. Can't see much of a problem. And consider this: a square sensor lets you utilize more of the lens' image circle every time you go from 3:2 or 4:3 toward squared ratios. And you gain AoV. So how I see it is that the advantages would heavily outweigh the costs.
A square sensor only lets you utilize more of the lens' image circle if your final image will be square. If your final image will be in a different aspect ratio, you would have been better off with a sensor of the matching aspect ratio that was sized for the image circle.

Square sensors are only the most efficient when producing square images.
Has anyone actually done a study to determine what percentage of images are presented in particular aspect ratios? If we had that information, we could determine what aspect ratio would be the best fit for typical images.
Shouldn't be too hard. On Instagram square is still popular in spite of them allowing rectangular nowadays. So actually the real surprise is that phones don't get square sensors either. Weird.
Probably the best sensor size would be a compromise. Not square, but not as wide as the wider aspect ratios. Something in the middle, biased towards the more common aspect ratios. That would be the shape that makes the most efficient use of the image circle across a wide range of typical images.

The goal would be to provide the best sensor for the most images.
 
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors?
Square peg … round hole. They won't fit perfectly no matter how you size them.

If you make the sensor fit entirely inside the image circle, it will be 30x30mm, which will result in a loss of sensor area for capturing 3:2 photos.

If you make the square large enough to allow a 36x24mm capture in either orientation, i.e. by making it 36x36mm, some parts of the sensor will be outside of the image circle and will be wasted. So the largest useful square capture area will still be 30x30mm. If you record readings from the entire sensor and view them as an image, the corners of that image will be dark or severely vignetted.

That is, a 36x36mm sensor forces a choice on you: waste part of it, or suffer vignetting, or redesign the camera system (including lenses) around it. You can pick your poison – but all of the options are poison.

An oversized hexagonal sensor will reduce waste compared to an oversized square one, but there will still be waste.
Let's say that you want to record 36mm x 36mm images.
But I don't. I want to record 30x30 in this example. So I can use my old lenses.
 
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors?
Square peg … round hole. They won't fit perfectly no matter how you size them.

If you make the sensor fit entirely inside the image circle, it will be 30x30mm, which will result in a loss of sensor area for capturing 3:2 photos.
Obviously. Not a good idea.
If you make the square large enough to allow a 36x24mm capture in either orientation, i.e. by making it 36x36mm, some parts of the sensor will be outside of the image circle and will be wasted. So the largest useful square capture area will still be 30x30mm. If you record readings from the entire sensor and view them as an image, the corners of that image will be dark or severely vignetted.
Of course.
That is, a 36x36mm sensor forces a choice on you: waste part of it
Now you got the idea.
or suffer vignetting, or redesign the camera system (including lenses) around it.
Wouldn't make any sense.
You can pick your poison – but all of the options are poison.
IMHO wasting part of the sensor is mild poison compared to how much of my lenses' IC I lose because camera makers insist on sticking to old film formats.
An oversized hexagonal sensor will reduce waste compared to an oversized square one, but there will still be waste.
That's an interesting idea. There are already 'wasteful' 'multi aspect' sensors (Panasonic GH2 and LX?). Wasting 33% of your sensor area may sound like much but they are different parts in different aspects. The always lost parts are small, just a bit off the corners. and the sensor size is still much smaller than the next format up which in the case of M43>APS doesn't seem to increase costs or size much if at all.
Let's say that you want to record 36mm x 36mm images.
But I don't. I want to record 30x30 in this example. So I can use my old lenses.
 
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors?
Square peg … round hole. They won't fit perfectly no matter how you size them.

If you make the sensor fit entirely inside the image circle, it will be 30x30mm, which will result in a loss of sensor area for capturing 3:2 photos.
Obviously. Not a good idea.
Here's the point you miss -- every aspect ratio except 1:1 loses with a 30x30mm sensor. Right now the 3:2 aspect ratio absolutely wins in terms of optimally utilizing sensor area for the biggest variety of alternative crops over 1:1 aspect ratio within the available image circle -- that's what my chart showed. Take some time to grasp that so it doesn't leave you confused.
If you make the square large enough to allow a 36x24mm capture in either orientation, i.e. by making it 36x36mm, some parts of the sensor will be outside of the image circle and will be wasted. So the largest useful square capture area will still be 30x30mm. If you record readings from the entire sensor and view them as an image, the corners of that image will be dark or severely vignetted.
Of course.
That is, a 36x36mm sensor forces a choice on you: waste part of it
Now you got the idea.
Then the idea here is that everyone pays for unused sensor area, and the sensor is the most expensive component in the camera, so that you can get more area for a couple of barely used aspect ratios.
or suffer vignetting, or redesign the camera system (including lenses) around it.
Wouldn't make any sense.
You can pick your poison – but all of the options are poison.
IMHO wasting part of the sensor is mild poison compared to how much of my lenses' IC I lose because camera makers insist on sticking to old film formats.
You should take a look at the edge performance of your lenses beyond what is captured on the sensor you are currently using them on. You can do this with an adapter and by putting them on a larger format sensor. I'm pretty sure you will be rather disappointed by what you see, I'm reasonably certain I would be.
An oversized hexagonal sensor will reduce waste compared to an oversized square one, but there will still be waste.
That's an interesting idea. There are already 'wasteful' 'multi aspect' sensors (Panasonic GH2 and LX?). Wasting 33% of your sensor area may sound like much but they are different parts in different aspects. The always lost parts are small, just a bit off the corners. and the sensor size is still much smaller than the next format up which in the case of M43>APS doesn't seem to increase costs or size much if at all.
Volume is a big part of cost, so if it's a low volume product it's going to cost more. Frankly, given the relative volume of m4/3 compared to APS-C/DX, and most of us don't know what the underlying costs or resulting profit margins are, I would be surprised if the smaller sensors don't actually cost more.

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Internet Interlocuter
 
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Then you have to have new lenses that project a larger image circle or your sensor always has significant vignetting and general weakness in its corners when using its native aspect ratio (which will also come up with the other aspect ratios too).
Yes if the sensor has to fit within the image circle but that is not necessary, better let it spill beyond:
That's not what he's saying. You can make a sensor as oversized as you like. It will not help you at all with vignetting issues if your lenses are standard full-frame lenses.
Ok I don't understand what photonut is Trying to say. What has vignetting to do with square sensors? They wouldn't behave differently WRT vignetting than rectangular ones. Unless you override the default aspect ratios and really want the whole thing with black corners and all. My idea is that the square version should accommodate the present formats thus be at least long side squared.
A square sensor that is covered by the current image circle of a FF lens would be just over 30mm x 30mm, not 36mm x 36mm. To be covered by an image circle, the diagonal of the sensor must be no greater than the diameter of the image circle. The diagonal of a 36mm x 24mm sensor is not quite 44mm, so we assume the image circle diameter to be about 44mm. A square sensor with the same diagonal is just over 30mm x 30mm. So if you made a 36mm x 36mm sensor, which has a diagonal of about 51mm, the corners of the sensor would extend 3,5mm beyond the outside of the image circle, and this wouls give you strong vignetting.
Even I would admit that nobody wants a 30x30 sensor for FF.
Well that's about the largest square sensor a current FF lens will reliably cover.
Ok I guess I need to spell it out once more: the only square sensor that makes any sense is one that allows present aspect ratios without compromising resolution in addition to the benefits for more square aspects, thus must be at least 36x36 for FF. Suitable sizes for APS and M43 respectively would be 24x24 and 18x18 (rounded upwards). The parts of the square that fall outside the IC are discarded by default. It's called an oversized sensor. I believe Panasonic has an LX something with one though it's not square.
So you want to put something like a 36MP 36mm x 36mm oversize sensor into a camera and use it to take 26MP square pictures, 25MP 4:3 pictures, 24MP 3:2 pictures and 22.5MP 16:9 pictures, using current FF lenses.
Precisely, except scaled down to M43 as that's what I have and can't afford a system upgrade.
You could possibly do this for m4/3, this from wikipedia "The usual size of the sensor is 18 mm × 13.5 mm (22.5 mm diagonal), with an imaging area of 17.3 mm × 13.0 mm (21.63 mm diagonal)." if you use the imaging area you would reduce the frame to 15.3 X 15.3mm to cover the image circle of a m4/3 lens, You gain a small amount on the height and loose a small amount on the width of a m4/3 format, is it really worth it over simply using the square format already available in m4/3 cameras.
I suppose you could do it with mirrorless, but not dSLRs, and only for lenses that had no baffles.
Those are the restrictions + some mounts block the "view" with the contacts. Not M43 or Pentax as far as I can see.
 

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