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Phosphor layer are essential in the application of phosphor-converted white light emitting diodes (pc-WLEDs). However, the conventional structure of red–green–blue (RGB) phosphor layers can cause severe re-absorption of blue light, resulting in low luminous efficiency and colour rendering index (CRI). In this paper, we fabricated a new WLEDs phosphor layer, which consisted of patterned RGB phosphor pixel arrays in a planar configuration, by the stencil printing technique. Optical simulation based on Monte-Carlo theory has been applied to assist designing the optimal pattern of the phosphor pixel arrays. By tuning the layout of the pixel arrays and the size of phosphor pixels, we achieved uniform output white light with high luminous intensity of 1.47 × 109 cd and CRI of 95.6, which are superior compared with the intensity of 1.11 × 109 cd and CRI of 93.5 obtained from WLEDs with conventional dispensing phosphor layer. Our newly-designed phosphor pixel-array layer possesses great potential for applications in advanced lighting and display devices with vast implications for industrial improvement in these research areas. [ABSTRACT FROM AUTHOR]