Many LED applications, such as in mobile phones and PDA's, require compact and highly efficient beam shaping elements. Micro-optical elements fabricated by UV-replication in a thin layer on a stable glass substrate offer attractive solutions for white LED's. Modeling tools have been developed to simulate and optimize micro-optical elements for extended white light sources. Experimental results of elements converting a Lambertian emitter into a Gaussian illuminance distribution are demonstrated. Wafer-scale UV-replication is the preferred technology for high volume fabrication. Additional process steps for applying mechanical mounting features as well as the integration to monolithic systems are described.

© 2004 Optical Society of America

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