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The new, LED curing lamps that (extravagant) dentists use to set light-cured fillings apparently use a LED cluster made from dozens of ultra-bright Philips LEDs which are somehow machined so that they fit together in a honeycomb arrangement, resulting in an extremely compact light source. So if major manufacturers do it, surely we can too
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Lumileds do powerful LED for this purpose, negating the need for LED clusters.
http://www.lumileds.com/products/line.cfm?lineId=15
As you say though not cheap -and a bit bright for magic eye applications
