Design of efficient freeform lenses for mass-market illumination applications using hybrid algorithms

We report on the development and experimental analysis of novel freeform polymer lenses for the uniform illumination of a target area using high-brightness LED. In a first step, the LED module was centered over the illuminated area and the two faces of a freeform lens were designed for homogeneous and efficient light distribution. In a second step, the system was extended for an off-axis target, the overall size was reduced and structures for automated alignment with respect to the LED were included. Photometric analyses were used for each system and were found to be in good agreement with simulations.