Abstract: Light-emitting articles and methods of manufacturing such articles are disclosed. In one aspect, a light emitting article includes an optical element having an input and an output aperture, each having a size. An LED die having a size is optically coupled to the optical element. The output aperture size of the optical element matches the LED die size. In another aspect, an array of light-emitting articles includes an array of optical elements having a lapped input aperture surface, and an array of LED dies optically coupled to the optical elements at the input aperture. In another aspect, an array of light-emitting articles includes an array of optical elements, and an array of LED dies, each LED die having a size. Each LED die is optically coupled to an optical element at the input aperture. The output aperture size of the optical element is matched to the LED die size.

Abstract: The present application discloses arrays of optical elements and methods of manufacturing same. In one aspect, an array of optical elements has a lapped input aperture surface. In another aspect, a mechanically stable array of optical elements comprises an array of optical elements. Each optical element has a sidewall and the sidewalls of adjoining optical elements form channels in the array. A protective material at least partially fills the channels in the array to form the mechanically stable array. In another aspect, a manufacturing method comprises providing an array of roughly shaped optical elements, each roughly shaped optical element having a sidewall, and the sidewalls of adjoining roughly shaped optical elements forming channels in the array; filling the channels with a removable protective material to form a mechanically stable array; and lapping the mechanically stable array to a final shape and surface finish to form the array of optical elements.

Abstract: Provided is an abrasive article for lapping or polishing a workpiece comprising a three-dimensional, textured, flexible, fixed abrasive construction having a first surface and a working surface, the working surface comprising a plurality of precisely shaped abrasive composites, wherein the precisely shaped abrasive composite comprises a resin phase and a metal phase, wherein the metal phase further comprises superabrasive material. Also provided are a method of polishing or lapping a workpiece and a kit comprising a three-dimensional, textured, flexible, fixed abrasive construction and instructions for carrying out the method of polishing or lapping a workpiece.

Abstract: Provided is a method of polishing comprising providing a workpiece, providing a fixed abrasive article, providing conditioning particles, and relatively moving the workpiece and the fixed abrasive article in the presence of the conditioning particles to modify the surface of the workpiece and to condition the fixed abrasive. The fixed abrasive article comprises a substrate having a first surface and a region of abrasive composites distributed on the first surface of the substrate. The abrasive composites include a composite binder and abrasive particles, which may be in abrasive agglomerates together with a matrix material. The abrasive particles are harder than the workpiece. The conditioning particles are sufficient to condition one or more of the composite binder, matrix material, and abrasive agglomerates. The hardness of the conditioning particles is less than the hardness of the workpiece and they do not substantially polish the workpiece.

Abstract: Provided is a fixed abrasive article for polishing a workpiece having a hardness comprising (a) a substrate having a first surface and a second surface, (b) a region of abrasive composites distributed on the first surface of the substrate, and (c) a region of conditioning amalgams distributed on the first surface of the substrate. The abrasive composites include a composite binder and abrasive particles of a first hardness, which first hardness is higher than the hardness of the workpiece. The amalgams include an erodible binder and conditioning particles sufficient to condition the composite binder and having a second hardness, which second hardness is less than the hardness of the workpiece and greater than the hardness of the composite binder. Also provided are other abrasive articles, and methods of making them.

Abstract: A method for fabricating an array of precisely shaped and located shaped elements utilizes a precisely shaped patterned abrasive to form channels in a workpiece. One or more patterned abrasives contact and abrade along one or more intersecting axes to define the shaped elements. The shaped elements may include optical elements, semiconductor elements, or both.