Beam shaping of incoherent light sources (LEDs, halogen lamps) for arbitrary target light distribution is obtained by a single free-shape mirror. Special design algorithm ensures continuous profile without abrupt changes and shadowing regions. The mirror is manufactured by single point diamond turning combined with Fast-Tool-Servo (FTS) for simultaneous figuring of base surface and fine structure (for redistributing the light energy). Lateral and axial resolution of the fine structure is determined by FTS and considered during the design and data transfer. Directly turned surfaces can be used as replication tools for polymer or glass moulding and embossing.© (2008) COPYRIGHT SPIE--The International Society for Optical Engineering. Downloading of the abstract is permitted for personal use only.