Many non-imaging and imaging reflective illumination designs work great on paper, but are either very expensive to manufacture or significantly underperform their designers expectation. We report here on our first results of a new, high volume capable, low cost manufacturing processes that can be customized to build a wide range of high performance reflective illumination components (imaging and non-imaging) with all or most performance parameters simultaneously improved. This flexible manufacturing technology is based on the combination of high surface shape capable metal substrate manufacturing process with a compatible surface roughness improvement (SRI) coating.
By example of an eele-enhanced lamp reflector module we will show that the manufacturing process improvements achieved for the projection display market are also capable of being adapted to manufacture higher performance, lower cost, reflective components for other illumination applications and wavelength ranges.
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