Freeform surface lens for LED uniform illumination

A method using a freeform surface lens for LED secondary optic design is proposed in this paper. By Snell's Law, the differential equations are given to build the relationship between the normal direction of a freeform surface and its input/output ray vectors. Runge-Kutta formulas are used to calculate the differential equations to design the freeform surface. Moreover, the optical model for uniform illumination is simulated and optical performance is analyzed. A practical freeform surface lens for LED uniform illumination is fabricated using an injection molding method. By the process, our system demonstrates a uniform illumination with a divergence half-angle of 6 degrees and an efficiency of 78.6%.