An array of housings with housing bodies and lenses is molded, or an array of housing bodies is molded and bonded with lenses to form an array of housings with housing bodies and lenses. Light-emitting diodes (LEDs) are attached to the housings in the array. An array of metal pads may be bonded to the back of the array or insert molded with the housing array to form bond pads on the back of the housings. The array is singulated to form individual LED modules.
STATEMENT OF GOVERNMENT SPONSORED RESEARCH
 One or more embodiments of this invention were made with Government support under contract no. DE-FC26-08NT01583 awarded by Department of Energy. The Government has certain rights in this invention.