Stereolithography 3D printing of transparent resin lens for high-power phosphor-coated WLEDs packaging

Advanced lens fabricating techniques are urgently required for the development of white light-emitting diodes (WLEDs) packaging, due to the traditional LED lenses molding possesses presents many disadvantages like high cost, long-fabrication period, less compactness and low accuracy. The current study demonstrated the fabrication of lenses with transparent resin utilizing stereolithography (SLA) 3D printing. The SLA 3D printing parameters were optimized to accurately regulate the spheric and ellipsoidal lenses with the smooth surface and the acceptable transmittance. The illuminances, lighting efficiency (LE) and lighting distribution curves of the SLA-fabricated lens packaged WLEDs highly depended on the lens structure. The WLEDs with lower lens height exhibited more intense lighting energy density, higher LE and wider light output angle. SLA 3D printing offers a flexible approach of fabricating WLED lens, which provides a novel technical route for WLEDs to meet different lighting requirements.

Automated summary

Advanced lens fabricating techniques are urgently needed for WLEDs packaging due to the disadvantages of traditional LED lenses molding. This study demonstrated the fabrication of lenses using transparent resin and SLA 3D printing. The parameters were optimized to achieve accurate regulation of the lenses and satisfactory transmittance. The lighting characteristics of the SLA-fabricated lens packaged WLEDs highly depended on the lens structure, with lower lens height resulting in higher lighting energy density, efficiency, and wider light output angle. SLA 3D printing provides a flexible approach for fabricating WLED lenses to meet different lighting requirements.