I posted the gerber I used to make a solder-paste stencil for this MCPCB on my blog. I used a Silhouette cutting plotter to cut the stencil out of some transparent polyester sheet.
Besides aspherics and other non-specific lenses which may work 0K, do you know of any lenses specifically designed for this sort of MCPCBs?
The distante between each 3535 pad is ≈0.3mm, this means emitter centers lay at (-1.9, 1.9), (1.9, 1.9) and etc. Off-center 3535 pad center distance is √(1.9² + 1.9²) = √7.22 (≈2.687mm), 3.8 × 3.8mm square for optical centers, 2√7.22 = ≈∅5.374mm circle.
For a single TIR to be fit around the quad its hole needs to be of almost 11mm, thus.
when making stencils for MCPCBs you should stick to the recommended ones in datasheet
often there is less % area covered on the current pads than on the DTP pad
so the LED gets some force pulling it down to the DTP pad
yours is the opposite