A method of fabricating an optical assembly includes providing a first mold having a first curved mold surface; placing a substantially flat reflective polarizer; on the first curved mold surface and applying at least one of pressure and heat to at least partially conform the reflective polarizer to the first curved mold surface; providing a second mold comprising a second mold surface, the first and second mold surfaces defining a mold cavity therebetween; substantially filling the mold cavity with a flowable material having a temperature greater than a glass transition temperature of the reflective polarizer; and solidifying the flowable material to form a solid optical element bonded to the reflective polarizer. A maximum variation of an orientation of a pass polarization state across the bonded reflective polarizer is within about 3 degrees of a maximum variation of the orientation of the pass polarization state across the substantially flat reflective polarizer.