The purpose of this study is to develop a procedure for the design and manufacture of compound surface condenser lens with LED light source. The design of lens surface is based on the geometrical optics theory and the application of NURBS function for its high degree of freedom of control points. The Tracepro optical software was used to perform the optical analysis and simulation of ray tracing and spot view. The material selected for study was polymethyl methacrylate (PMMA) for its excellent optical properties. In the manufacture of prototype, the five-axis machining center was used to machine the complex free form surface and a thermal melting process was used to restore the optical transmission properties of the material. The case study showed that the developed procedure is feasible.