Novel fabrication method of LED freeform lens based on electrohydrodynamic

We present a novel fabrication method of LED freeform lens which is used to accelerate the process and reduce cost. Firstly, we can get the structure of freeform surface by simulation. Based on energy mapping and Snell' law, we can obtain the discrete points of freeform surface. Then structure of freeform surface can be obtained by lofting the discrete points. Second, we preprocess the generated freeform surface to adapt fluid fabrication process. Meanwhile, electrode parameters including electrode length, space and voltage can be deduced based on the structure of freeform surface. Third, a silicone lens is generated by electrohydrodynamic processing method. Light performance of the lens is tested compared with the simulation result. Results demonstrate the experiment result is close to simulation, so electrohydrodynamic processing method is feasible for LED fabrication process.