Patent ID: 7452737

Claim:
A method for forming an optical element over a light emitting diode (LED) die comprising: providing a plurality of non-encapsulated LED dies mounted on a single submount support structure, the support structure having metal leads in electrical contact with metal contacts on each LED die, the LED dies forming a two-dimensional pattern on the support structure; providing a first mold having indentations corresponding to the pattern of LED dies on the support structure; filling the indentations in the first mold with a liquid first lens material prior to the LEDs dies being positioned within the indentations; bringing the first mold and the support structure together so that the LED dies are within the liquid first lens material so as to directly contact the liquid lens material; curing the liquid first lens material until it hardens; removing the support structure from the first mold so that a first lens formed from the hardened first lens material overlies each of the LED dies and fully encapsulates each of the LED dies; and singulating the submount support structure into portions, wherein mounted on each portion is at least one encapsulated LED die.