In the past two decades, solid-state lighting has steadily expanded to outperform many traditional lighting technologies due to its higher energy efficiency, longer lifetime, and reduced maintenance. The effectiveness of a solid-state lighting design for a given application relies upon the optimum use of its sub-components. An LED lighting system uses an optical subsystem with secondary optics to optimize the total luminous flux on the application surface, thus increasing its application efficiency. Therefore, it is essential to use well-defined secondary optics to achieve desired illumination patterns, luminous efficiency, and lighting uniformity. Hence, this study focused on developing a 3D printable refractive lens structure that collects luminous flux from the LED light source and redirects it into the spherical lens array. Subsequently, the spherical refractive array structures are designed in the lens to redirect the accumulated luminous flux onto the target plane to increase the application efficacy and uniformity. The designed lens is later fabricated using 3D printing to perform the experimental study. The results confirm the possibility of using a refractive array lens with a backend structure to achieve higher application efficacy.
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