In this paper, we demonstrated the machining process of a novel Light Emitting Diodes (LED) beam shaping lens, called TIR Fresnel lens, for GaN-based blue Chip Scale Packaged (CSP) LEDs. Upon achieving a precise alignment of the tool and identifying the best manufacturing condition, we have successfully fabricated a prototype of this lens on poly methyl methacrylate (PMMA) plate. The form error of the central aspheric lens was less than 1 μm deviation, and surface quality of the Fresnel facets were sufficient for Total Internal refraction without any burr or adhesion of the machined chip. Fabricated TIR Fresnel lens reduced the viewing angle of the testing CSP LED from 140° to 17.4° in FWHM. The proposed lens produced extreme compactness as well as high collimation efficiency, thereby applicable to an ultra-thin optical system.
Theoretical analysis and optimization of 3D laser beam shaping