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In this contribution we discuss a smart design of an extremely flat direct-lit luminaire for general lighting applications. The main advantage of this concept is the increased DHR ratio compared to diffuser sheet only-approaches and a smaller thickness of the whole set-up compared to common freeform approaches. For this demand we have designed very thin freeform optical elements with a maximal height of 75 μm that allow to maintain a uniform illumination in direct-lit applications using an LED-array with a comparably large distance between the individual LEDs. The presented design concept in addition emphasizes the use of cost-effective manufacturing methods like grey scale laser lithography for mastering and roll-to-roll processing for large area manufacturing of these optical elements.
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