Abstract: A modular method of manufacturing a waveguide is disclosed. The method includes positioning a mold insert including a plurality of mold prototypes, along at least one side wall of a molding equipment such that micro-optic structures of each mold prototype in the plurality of mold prototypes, faces a mold cavity. Each mold prototype extends along a length of the mold insert and the plurality of mold prototypes is disposed adjacent one another along a height of the mold insert. The method further includes feeding a material into the mold cavity for molding the material in the mold cavity to generate waveguide including a major surface having an optical pattern, where the optical pattern includes a plurality of elongated facets. Each of the plurality of elongated facets extends into the major surface and along a length of the waveguide. Further, the optical pattern extends along a height of the waveguide.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: Waveguides having improved illumination distribution and output luminance variation and lighting systems utilizing such waveguides are disclosed. The lighting systems generally include a light source which is optically coupled to a waveguide to distribute the light. The waveguides include one or more headlighting reduction regions and one or more output intensity shaping regions that work together to improve the distribution of light and reduce the effects of headlighting. The headlighting reduction regions may be integrated with the output intensity shaping region or may be an independent section.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: A composite core die includes a reusable core die and a disposable core die; where the disposable core die is in physical communication with the reusable core die; and further where surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: A method of forming an integral casting core includes adding a disposable insert to a metal core die and disposing a slurry into the metal core die. The slurry includes ceramic particles. The method further includes firing the slurry to form a integral casting core and removing the disposable insert from the integral casting core.

Abstract: Disclosed herein too is a method of forming an integral casting core comprising adding a disposable insert to a metal core die; disposing a slurry into the metal core die; wherein the slurry comprises ceramic particles; firing the slurry to form a integral casting core; and removing the disposable insert from the integral casting core.

Abstract: Disclosed herein is a composite core die comprising a reusable core die; and a disposable core die; wherein the disposable core die is in physical communication with the reusable core die; and further wherein surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.