具体实施方式：
[0044]Generally, there is disclosed herein three-dimensional (3D) printed integrated thermal management and light transfer structures. The integrated thermal management and light transfer structures may be included in a luminaire (i.e., light fixture). The thermal management structure may include a thermal transfer structure. The thermal transfer structure may include, but is not limited to, a heat sink. The light transfer structure may include, but is not limited to, a reflector, a diffuser, a lens and/or a combination thereof.
[0045]The thermal management structure may be configured to manage a thermal output from one or more sources including, but not limited to, a light source (e.g., a light engine including one or more LED(s), drive electronics, etc.). In one nonlimiting example, the thermal management structure (e.g., heat transfer structure) may be configured to reduce a light emitting diode (LED) junction temperature or to maintain a relatively low LED junction temperature. In one nonlimiting example, the thermal management structure may include a heat sink. In another example, the thermal management structure may correspond to a heat sink.
[0046]The light transfer structure may be configured to facilitate transmission of light energy emitted by the light source, out of the luminaire and onto a lighting target. Function(s) of the light transfer structure may include, but is(are) not limited to, tailoring a beam distribution of the luminaire, i.e., beam forming (e.g., lighting application-specific beam forming), increasing efficacy of the luminaire, providing or enhancing decorative aspects of the luminaire, etc.
[0047]The thermal management structure and light transfer structure may be manufactured in a same 3D printing process. In an embodiment, the thermal management structure and light transfer structure may be separate structures manufactured into a single 3D printed component during the 3D manufacturing process. The single 3D printed component may then include a plurality of portions with at least one portion corresponding to the thermal management structure and at least one other portion corresponding to the light transfer structure. In this embodiment, the thermal management structure and light transfer structure are each configured to maintain a respective, independent functionality.
[0048]In another embodiment, the thermal management structure and light transfer structure may be combined into a same 3D printed component. In this embodiment, the thermal management structure and light transfer structure may correspond to the same 3D printed component. Combining different subassemblies into an integrated 3D printed component (i.e., integrated structure) can reduce an overall luminaire manufacturing cost. In one nonlimiting example, a reflector or diffuser (light transfer structure) may be combined with a heat sink (heat transfer structure) into a single component that can be 3D printed.
[0049]In an embodiment, there is provided a luminaire. The luminaire includes a light engine, a light transfer structure and a thermal management structure. The light engine includes at least one LED. The light transfer structure is configured to receive light from the light engine. The thermal management structure is configured to manage a thermal energy of the light engine. The light transfer structure and the thermal management structure are formed during a same three-dimensional (3D) printing process.
[0050]It may be appreciated that using 3D printing to create luminaires has many benefits including, but not limited to, being available on-demand, facilitating creation of custom luminaires, and/or on-site manufacturability. Additionally or alternatively, benefits may further include reducing a number of parts when manufacturing a luminaire that may then result in significant cost reduction. Additionally or alternatively, benefits may further include reduced labor and/or increased manufacturing consistency.
[0051]It may be appreciated that manufacturing details associated with 3D printing are 3D printer-specific and may vary according to 3D printer technology, characteristics (e.g., shape, size, etc.) of the structure(s) to be printed and/or materials used in the 3D printing process. Integrated thermal management and light transfer structures, consistent with the present disclosure, are configured to be 3D printed using an appropriate 3D printing process.
[0052]It may be appreciated that at least some thermal management structures (e.g., heat sink(s)) may be configured to transfer heat from a heat source (e.g., a light engine). Heat transfer characteristics of the thermal management structure are related to thermal characteristics (e.g., thermal conductivity) of each material included in the thermal management structure. For example, a polymer may have an associated relatively low thermal conductivity, and a metal may have an associated relatively high thermal conductivity.
[0053]In some embodiments, the thermal management structure may be 3D printed using a composite material that includes first material that has relatively low thermal conductivity and a second material that has relatively high thermal conductivity. As used herein, a relatively low thermal conductivity corresponds to thermal conductivity less than about one watt per meter-kelvin (W/(m·K), and a relatively high thermal conductivity corresponds to thermal conductivity greater than about 10 W/(m·K). As used herein, relatively low conductivity materials may include, but are not limited to, synthetic polymers (e.g., nylon, polyethylene, polyester, etc.). As used herein, relatively high conductivity materials may include, but are not limited to, metals (e.g., copper, zinc, brass, aluminum, etc.), carbon, etc. The second material may be configured to enhance the thermal conductivity of the thermal management structure. The composite material may then possess thermal characteristics suitable for the thermal management structure. The second material (i.e., the relatively high thermally conductive material) may include, but is not limited to, metal particles, nanoparticles (e.g., carbon nanotubes, metal nanoparticles), etc.
[0054]In some embodiments, a thermal management structure may include one or more thermal management elements. In one nonlimiting example, for a thermal management structure that is a heat sink, the thermal management elements may be heat sink fins. However, this disclosure is not limited in this regard. Each thermal management element, consistent with the present disclosure, may include a composite material that includes a first material and a second material. The second material may be configured to enhance a thermal conductivity of the thermal management element and, thus, the thermal management structure. In one nonlimiting example, the first material may include a polymer and the second material may include a plurality of relatively thermally conductive particles.
[0055]Thus, a thermal management structure, according to the present disclosure, is configured to be relatively thermally conductive. A target thermal conductivity may be achieved by 3D printing the thermal management structure using a single material with an appropriate thermal conductivity or a composite material with the appropriate thermal conductivity.
[0056]FIG. 1A is a sketch 100 illustrating an isometric view of an example luminaire that includes integrated thermal management and light transfer structures, according to several embodiments of the present disclosure. Example luminaire 100 includes a first thermal management structure 102-1 and a second thermal management structure 102-2. The first thermal management structure 102-1 and the second thermal management structure 102-2 may be 3D printed of a single material or a composite material, as described herein. In this example 100, the first thermal management structure 102-1 is contiguous at a bottom edge with a top edge of the second thermal management structure 102-2. As used herein, “top”, “bottom”, and “side” are terms of convenience configured to indicate relative position, and not necessarily orientation in space.
[0057]The first thermal management structure 102-1 includes a plurality of thermal management elements 104-1, 104-2, 104-3. Each thermal management structure 102-1, 102-2 defines at least one thermal management feature 106-1, 106-2, . . . , 106-n, 108-1, 108-2. In this example luminaire 100, a first thermal management element 104-1 defines two thermal management features 106-1, 106-2, a second thermal management element 104-2 defines one thermal management feature 106-3, and a third thermal management element 104-3 defines two thermal management features 106-4, 106-5. The second thermal management structure 102-2 defines at least one thermal management feature, e.g., thermal management feature 106-n. Each thermal management feature 106-1, 106-2, . . . , 106-n, 108-1, 108-2 may be configured to facilitate airflow, and thus thermal management, of an associated thermal energy source, e.g., light engine. As used herein, “light engine” may include a single light source (e.g., LED) or a plurality of light sources (e.g., a plurality of LEDs arranged in an LED array).
[0058]In this example 100, the first thermal management structure 102-1 has a generally cylindrical shape and the plurality of thermal management elements 104-1, 104-2, 104-3 are arranged as concentric cylinders. However, this disclosure is not limited in this regard. The first thermal management element 104-1 and the second thermal management element 104-2 are separated by a first thermal management feature 108-1. The second thermal management element 104-2 and a third thermal management element 104-3 are separated by a second thermal management feature 108-2. In one nonlimiting example, the first and second thermal management features 108-1, 108-2 may correspond to voids, configured to allow or facilitate air flow to an ambient environment from the luminaire 100. Relative sizes (i.e., dimensions) of the thermal management elements and the thermal management features may be configured to facilitate thermal management functionality of the thermal management structure. For example, a heat sink may generally include thermal management elements that have a relatively high surface area and thermal management features that are relatively high volume. As is known, such a heat sink structure is configured to facilitate heat sinking functionality of the heat sink.
[0059]In some embodiments, a shape of the first thermal management structure 102-1, and/or shape(s) of one or more of the thermal management elements 104-1, 104-2, and/or 104-3, may be cylindrical, ellipsoidal, rectangular, square, or free-form shaped. In some embodiments, the first thermal management structure 102-1, and/or one or more of the thermal management elements 104-1, 104-2, and/or 104-3, may have a non-uniform cross section, may include segments of equal or unequal lengths, and/or may include one or more random geometries. It may be appreciated that the 3D printing process facilitates implementing a broad range of geometries for the first thermal management structure 102-1, and one or more of the thermal management elements 104-1, 104-2, and/or 104-3.
[0060]The second thermal management structure 102-2 has a generally truncated conical (i.e., frustum conical) shape. However, this disclosure is not limited in this regard. The second thermal management structure 102-2 has a first side boundary 112-1, a second side boundary 112-2, a top boundary 114-1, and a bottom boundary 114-2. The top boundary 114-1 corresponds to the top edge of the second thermal management structure 102-2 and the bottom edge of the first thermal management structure 102-1. In this example 100, the top boundary 114-1 and the third thermal management element 104-3 have a diameter, D1, and the second thermal management structure 102-2 has a height, measured between the top boundary 114-1 and the bottom boundary 114-2, of H1. In this example 100, the height is uniform, however, this disclosure is not limited in this regard, thus, in other examples, the height may vary.
[0061]The first side boundary and the second side boundary 112-1, 112-2, extend between the top boundary 114-1 at the first thermal management structure 102-1 and the bottom boundary 114-2. The first side boundary and the second side boundary 112-1, 112-2, in this example, are generally linear. However, this disclosure is not limited in this regard. The top boundary114-1 and the bottom boundary 114-2 have a generally curved shape. However, this disclosure is not limited in this regard. In some embodiments, the first side boundary and the second side boundary 112-1, 112-2 may have a generally curved shape (e.g., convex, concave, parabolic), may be non-uniform and/or may be freeform, and/or may include and/or define one or more decorative feature(s). In some embodiments, the top boundary 114-1 and the bottom boundary 114-2 may be linear, may be non-uniform, and/or may include and/or define one or more decorative feature(s). It may be appreciated that the 3D printing process facilitates implementing a broad range of geometries for the second thermal management structure 102-2, and one or more of the first side boundary 112-1, the second side boundary 112-2, the top boundary 114-1 and/or the bottom boundary 114-2.
[0062]In this example 100, each thermal management feature 106-1, 106-2, . . . , 106-n has a generally rectangular shape. In some embodiments, the thermal management features 106-1, 106-2, . . . , 106-n may be generally circular, ellipsoidal, square, asymmetric, hexagonal, octagonal, random, etc. As used herein, “generally” when applied geometric shapes means to within manufacturing tolerances. In some embodiments, one or more of the thermal management features 106-1, 106-2, . . . , and/or 106-n may be decorative.
[0063]FIG. 1B is a cross-section A-A′ view 150 of the example luminaire 100 of FIG. 1A. Luminaire cross-section 150 includes the first thermal management structure 102-1 and the second thermal management structure 102-2, as well as corresponding elements and features described with respect to luminaire 100 of FIG. 1A. Luminaire cross-section 150 further illustrates thermal management features 106-1, 106-2, 106-3, 106-4, and 106-5 that, in this example 150, correspond to slots or cavities defined in the corresponding thermal management elements 104-1, 104-2, 104-3.
[0064]Luminaire 150 further includes thermal management features 106-n-1, and 106-n that, in this example 150, correspond to channels defined in the second thermal management structure 102-2. Channel 106-n has a first end 152-1 and an opposing second end 152-2. The first end 152-1 corresponds to an opening defined in the second thermal management structure 102-2. The second end 152-2 corresponds to an opening defined in the second thermal management structure 102-2 that is aligned with the first thermal management feature 108-1 defined in the first thermal management structure 102-1. The second end 152-2 is contiguous with the top edge of the second thermal management structure 102-2 that is contiguous with the bottom edge of the first thermal management structure 102-1. The thermal management features 106-n-1, 106-n are configured to facilitate transfer of thermal energy between the second thermal management structure 102-2 and the first thermal management structure 102-1. In one nonlimiting example, channels 106-n-1, 106-n, may facilitate transfer of thermal energy via convection. For example, ambient air may enter channel 106-n at the first end 152-1 and may exit the channel 106-n at the second end 152-2.
[0065]Luminaire 150 further includes a plurality of light sources 154-1, 154-2, 154-3. In one nonlimiting example, the light sources may be LEDs. This example luminaire 150 includes three light sources, however, more or fewer light sources may be included in luminaire 150, within the scope of the present disclosure. As used herein, the plurality of light sources corresponds to a light engine. Luminaire 150 further includes respective drive electronics 156-1, 156-2, 156-3 associated with each light source 154-1, 154-2, 154-3. The second thermal management structure 102-2 and first thermal management structure 102-1 may then be configured to manage thermal energy produced by the light sources 154-1, 154-2, 154-3 and/or the drive electronics 156-1, 156-2, 156-3. The thermal management may be facilitated by channels 106-n-1, 106-n. For example, channels 106-n-1, 106-n may correspond to internal air passages configured to facilitate convective cooling of the first thermal management structure 102-1 and thermal management elements 104-1, 104-2, 104-3.
[0066]Luminaire 150 further includes a light transfer structure 158. Light transfer structure 158 may include, but is not limited to, a coating, and/or a sheet insert. In an embodiment, the light transfer structure 158 may be 3D printed generally simultaneously with the second thermal management structure 102-2. Light transfer structure 158 has a surface 160 opposing the thermal management structure 102-2. Light transfer structure surface 160 has a surface characteristic configured to manage the transfer of light emitted from the light sources and out of the luminaire 150. In one nonlimiting example, the surface characteristic may be provided by a finish. For example, the finish may be relatively highly specular. In another example, the finish may be diffuse. The light transfer structure 158 is configured to receive light emitted from the light sources 154-1, 154-2, 154-3 and to transfer the received light out of the luminaire 150. Characteristics of the transferred light may be related to surface characteristics of the light transfer structure 158, e.g., whether the surface 160 is specular, diffuse, or a combination thereof. In some embodiments, the light transfer structure 158 and corresponding surface 160 may be configured to beam form the light exiting the luminaire 150. In some embodiments, the beam forming may be related to a lighting target, e.g., work space, art work, etc.
[0067]Thus, example luminaire 100, 150 may include a light transfer structure, e.g., light transfer structure 158, and a thermal management structure, e.g., thermal management structures 102-1, 102-2, that may be formed during a same 3D printing process.
[0068]FIG. 2A is a sketch 200 illustrating an isometric view of another example luminaire that includes integrated thermal management and light transfer structures, according to several embodiments of the present disclosure. Example luminaire 200 includes first and second thermal management structures 102-1, 102-2, as described herein. Example luminaire 200 further includes a third thermal management structure 202-1 and a fourth thermal management structure 202-2. The third thermal management structure 202-1 and the fourth thermal management structure 202-2 may be 3D printed of a single material or a composite material, as described herein. The third thermal management structure 202-1 is coupled to the second thermal management structure 102-2 at or near the bottom boundary 114-2. In this example 200, the bottom boundary 114-2 has a diameter, D2.
[0069]In this example 200, the third thermal management structure 202-1 has a generally annular shape with an outer annulus radius, R21, and an inner annulus radius, R22. However, this disclosure is not limited in this regard. An inner boundary 214-1 of the third thermal management structure 202-1 generally corresponds to the bottom boundary 114-2 of the second thermal management structure 102-2. An outer boundary 214-2 of the third thermal management structure 202-1 extends outside the bottom boundary 114-2 of the second thermal management structure 102-2. The third thermal management structure 202-1 defines a plurality of thermal management features 206-1, 206-2. The thermal management features 206-1, 206-2 may include, but are not limited to, voids, slots, holes, etc. The thermal management features 206-1, 206-2 are configured to facilitate airflow, and thus thermal management, of an associated thermal energy source, e.g., LED(s) and/or light engine.
[0070]The fourth thermal management structure 202-2 includes a plurality of thermal management elements 208-1, 208-2, . . . , 208-n-1, 208-n, coupled to, and in thermal communication with, the third thermal management structure 202-1. The plurality of thermal management elements 208-1, 208-2, . . . , 208-n-1, 208-n may be distributed about the third thermal management structure 202-1, along a surface of the third thermal management structure, opposing the second thermal management structure 102-2. The plurality of thermal management elements 208-1, 208-2, . . . , 208-n-1, 208-n may be configured to facilitate flow of thermal energy from the luminaire 200. In some embodiments, the thermal management elements 208-1, 208-2, . . . , 208-n-1, 208-n may include and/or may correspond to decorative features.
[0071]FIG. 2B is a cross-section B-B′ view 250 of the example luminaire 200 of FIG. 2A. Luminaire cross-section 250 includes the first thermal management structure 102-1 and the second thermal management structure 102-2, as described herein. Luminaire cross-section 250 further includes the third thermal management structure 202-1 and the fourth thermal management structure 202-2, as well as corresponding elements and features described with respect to luminaire 200 of FIG. 2A.
[0072]The third thermal management structure 202-1 further defines a plurality of thermal management features 206-n-1, 206-n. The thermal management features 206-n-1, 206-n may include, but are not limited to, voids, slots, holes, etc. The thermal management features 206-n-1, 206-n are configured to facilitate airflow, and thus thermal management, of an associated thermal energy source, e.g., LEDs 154-1, 154-2, 154-3. The fourth thermal management structure 202-2 includes a plurality of thermal management elements 210-1, . . . , 210-n, 212-1, . . . , 212-n. A first group of thermal management elements 208-1, . . . , 208-n may have a generally trapezoidal cross-section. A second group of thermal management elements 210-1, . . . , 210-n may have a generally triangular cross section. A third group of thermal management elements 212-1, . . . , 212-n may have a generally rectangular cross-section. However, this disclosure is not limited in these regards. The first group 208-1, . . . , 208-n may be generally positioned along the outer edge 214-2 of the annular third thermal management structure 202-1. The third group 212-1, . . . , 212-n may be generally positioned along the inner edge 214-1 of the annular third thermal management structure 202-1. The second group 210-1, . . . , 210-n may generally be positioned between the first group and the third group. The thermal management elements 208-1, . . . , 208-n, 210-1, . . . , 210-n, 212-1, . . . , 212-n may be configured to facilitate transfer of thermal energy from luminaire 250. Additionally or alternatively, the thermal management elements may correspond to, and/or be configured to provide, decorative features.
[0073]Thus, example luminaire 200, 250 may include a light transfer structure, e.g., light transfer structure 158, and a thermal management structure, e.g., thermal management structures 102-1, 102-2, 202-1, 202-2 that may be formed during a same 3D printing process. In some embodiments, at least a portion of the thermal management elements included in the thermal management structures may be configured to provide decoration.
[0074]FIG. 3A is a sketch 300 illustrating an isometric view of an example luminaire that includes integrated thermal management and light transfer structures, according to several embodiments of the present disclosure. Example luminaire 300 includes a first thermal management structure 302-1 and a second thermal management structure 302-2. The first thermal management structure 302-1 and the second thermal management structure 302-2 may be 3D printed of a single material or a composite material, as described herein. The first thermal management structure 302-1 includes a plurality of thermal management elements 304-1, 304-2, 304-3.
[0075]In this example 300, the first thermal management structure 302-1 has a generally cylindrical shape and the plurality of thermal management elements 304-1, 304-2, 304-3 are arranged as concentric cylinders. However, this disclosure is not limited in this regard. A first thermal management element 304-1 has a wall thickness of T1. A second thermal management element 304-2 has a wall thickness of T2. A third thermal management element 304-3 has an outer diameter, D1, and a wall thickness of T3. In some embodiments, the wall thicknesses T1, T2, T3 may be equal. In some embodiments, one or more of the wall thicknesses may not be equal to one or more other wall thickness(es). The wall thickness(es) T1, T2, and/or T3 may be related to thermal management characteristics of thermal management structure 302-1. For example, the wall thicknesses may be related to a rate of transfer of thermal energy from the first thermal management structure 302-1.
[0076]The first thermal management element 304-1 and the second thermal management element 304-2 are separated by a first thermal management feature 308-1. The second thermal management element 304-2 and the third thermal management element 304-3 are separated by a second thermal management feature 308-2. In one nonlimiting example, the first and second thermal management features 308-1, 308-2 may correspond to voids, configured to allow or facilitate air flow to an ambient environment from the luminaire 300.
[0077]In some embodiments, the first thermal management structure 302-1, and/or one or more of the thermal management elements 304-1, 304-2, and/or 304-3, may be cylindrical, ellipsoidal, rectangular, or square shaped. In some embodiments, the first thermal management structure 302-1, and/or one or more of the thermal management elements 304-1, 304-2, and/or 304-3, may have a non-uniform cross section, may include segments of equal or unequal lengths, and/or may include one or more random geometries. It may be appreciated that the 3D printing process facilitates implementing a broad range of geometries for the first thermal management structure 302-1, and one or more of the thermal management elements 304-1, 304-2, and/or 304-3.
[0078]The second thermal management structure 302-2 has a generally truncated conical (i.e., frustum conical) shape. However, this disclosure is not limited in this regard. The second thermal management structure 302-2 has a first side boundary 312-1, a second side boundary 312-2, a top surface 314-1, and a bottom boundary 314-2. The top surface 314-1 corresponds to a top boundary of the second thermal management structure 302-2. In this example 300, the top surface 314-1 has a generally circular shape with a diameter, D3. The diameter, D3, of the top surface 314-1 is greater than the diameter, D1, of the third thermal element 304-3. The second thermal management structure 302-2 has a height, H3, measured between the top surface 314-1 and the bottom boundary 314-2. It may be appreciated that the height H3 is less than the corresponding height, H1, of example luminaire 100, 150, of FIGS. 1A and 1B. In this example 300, the height, H3, is uniform, however, this disclosure is not limited in this regard, thus, in other examples, the height, H3, may vary.
[0079]The first side boundary and the second side boundary 312-1, 312-2, extend between the top surface 314-1 and the bottom boundary 314-2. The first side boundary 312-1 and the second side boundary 312-2 are generally linear. However, this disclosure is not limited in this regard. The top surface 314-1 and the bottom boundary 314-2 have a generally curved shape. However, this disclosure is not limited in this regard. In some embodiments, the first side boundary 312-1 and the second side boundary 312-2 may have a generally curved shape (e.g., convex, concave, parabolic), may be non-uniform and/or may be freeform, and/or may include and/or define one or more decorative feature(s). In some embodiments, the bottom boundary 314-2 may be linear, may be non-uniform, and/or may include and/or define one or more decorative feature(s). It may be appreciated that the 3D printing process facilitates implementing a broad range of geometries for the second thermal management structure 302-2, and one or more of the first side boundary 312-1, the second side boundary 312-2, the top surface 314-1 and/or the bottom boundary 314-2.
[0080]FIGS. 3B and 3C are two example 330, 360 cross-section C-C′ views that correspond to the example luminaire 300 of FIG. 3A. A first example luminaire 330 is configured to illustrate generally uniform and linear light transfer elements. A second example luminaire 360 is configured to illustrate non-uniform and/or nonlinear light transfer elements. The following description may be best understood when considering the first example luminaire 330 and the second example luminaire 360 together. The first example luminaire 330 includes the first thermal management structure 302-1 and a second thermal management structure 331. The second example luminaire 360 includes the first thermal management structure 302-1 and a third thermal management structure 361. The second thermal management structure 331 is one example of the second thermal management structure 302-2 of FIG. 3. The third thermal management structure 361 is another example of second thermal management structure 302-2.
[0081]Example luminaire 330 includes a plurality of light subassemblies 332-1, 332-2, 332-3. Each light subassembly 332-1, 332-2, 332-3 includes a respective light source 334-1, 334-2, 334-3, respective drive electronics 336-1, 336-2, 336-3, and a respective light transfer structure 338-1, 338-2, 338-3. Each light transfer structure 338-1, 338-2, 338-3 has a respective surface 340-1, 340-2, 340-3, opposing the second thermal management structure 331. Similarly, example luminaire 360 includes a plurality of light subassemblies 362-1, 362-2, 362-3. Each light subassembly 362-1, 362-2, 362-3 includes a respective light source 334-1, 334-2, 334-3, respective drive electronics 336-1, 336-2, 336-3, and a respective light transfer structure 368-1, 368-2, 368-3. Each light transfer structure 368-1, 368-2, 368-3 has a respective surface 370-1, 370-2, 370-3, opposing the third thermal management structure 361. Each light source 334-1, 334-2, 334-3, may correspond to light source 154-1 and each drive electronics 336-1, 336-2, 336-3, may correspond to drive electronics 156-1, as described herein.
[0082]Each light subassembly 332-1, 332-2, 332-3 of luminaire 330 includes a generally linear and generally uniform light transfer structure, e.g., light subassembly 332-1 includes light transfer structure 338-1. Each light subassembly 362-1, 362-2, 362-3 of luminaire 360 includes a respective, generally nonlinear (e.g., curved) light transfer structure 368-1, 368-2, 368-3. Additionally or alternatively, the light transfer structures 368-1, 368-2, 368-3 may be non-uniform. As used herein, “non-uniform”, when used in reference to a plurality of light transfer structures included in a luminaire, means geometries and, thus light transfer characteristics, may differ between at least some of the plurality of light transfer structures. The nonlinear and/or non-uniform light transfer structures may be configured to facilitate the beam forming for, for example, a selected lighting application.
[0083]Thus, example luminaires 300, 330, 360 may include a thermal management structure, e.g., thermal management structures 302-1, 302-2, 331-2, 361-2, and a light transfer structure, e.g., light transfer structures 338-1, 338-2, 338-3, 368-1, 368-2, 368-3, that may be formed during a same 3D printing process.
[0084]FIG. 4A is a sketch 400 illustrating an outline view of an example luminaire that includes integrated thermal management and light transfer structures, according to several embodiments of the present disclosure. Example luminaire 400 includes a first thermal management structure 402 and a light transfer structure 404. The first thermal management structure 402 may be 3D printed of a single material or a composite material, as described herein. In this example 400, the first thermal management structure 402 is separate from and coupled to the light transfer structure 404. In one nonlimiting example, the first thermal managemen