Abstract: A prosthetic eye or aesthetic contact lens and methods of manufacture of the same using additive manufacturing. Methods may include scanning a functional eye of a user to generate a prosthetic eye model matching the coloring and sizing features of the scanned eye. A substrate is positioned relative to one or more print heads, which deposit polymerizable mixtures as deposited droplets to form the sclera portion, vein pattern, and iris structure. A first polymerizable mixture may replicate a natural sclera, a second polymerizable mixture may form natural features, such as vein patterns, and a third polymerizable mixture may create an iris with a pupil region. The prosthetic eye may include an internal cavity filled with a liquid solution to allow iris movement, liquid pouches for hydration or medication, and integrated electronic components such as cameras, sensors, and wireless communication modules.

Abstract: A method of producing an ophthalmic lens including depositing polymerizable mixture onto a receiving surface of a substrate that is positioned within a package, layering the polymerizable mixture in one or more passes of an additive print head over the substrate where the layers form a three-dimensional structure of the ophthalmic lens, and curing the deposited mixture by exposing it to an actinic radiation, thereby initiating polymerization and forming a solid form of the ophthalmic lens. The method further requires sealing the substrate and formed ophthalmic lens within the package in a dry, non-hydrated state, where the formed ophthalmic lens remains adhered to the receiving surface, and shipping the sealed package having the substrate and formed ophthalmic lens therein in the dry, non-hydrated state.

Abstract: Methods and systems for determining control inputs to a manufacturing apparatus to manufacture a product are described. A processor may receive model data including initial state data indicating an initial state of an input material, a set of model control inputs, and target measurement data associated with a target product. The processor may learn a causal predictive model based on the target data. Each state of the causal predictive model may be based on an application of the model control inputs on a previous state of the causal predictive model. The processor may compare a final state of the causal predictive model with the target measurement data to determine a difference. The processor may determine, based on the difference, a set of control inputs to be assigned to one or more controls. The one or more controls may define a design of the manufacturing process of an end product.

Abstract: This invention provides for the fabrication of ophthalmic lenses via the utilization of DMD shows and/or DMD files. More specifically, the use of the DMD shows and/or DMD files to generate lens precursor designs comprising described features to form part of a substructure for the fluid reactive media portion of the lens precursor and wherein the lens precursor can generate particular ophthalmic lens designs in a free-form manner using methods described herein.

Abstract: A contact lens having a lens edge defining an outer periphery of the contact lens, an optic zone positioned within the lens edge designed to provide corrective vision for a patient, a Lens Center having a vertical axis and a horizontal axis passing therethrough, and first and second fiducial indicators present at first and second different locations around the lens edge. The first and second fiducial indicators each include at least one recess into or at least one projection extending outwardly from the lens edge and are different from one another.

Abstract: A Free-form contact lens and method of making the same. The lens includes a posterior optical quality surface having a concave shape, an opposing anterior surface having a convex shape both of which join at a lens edge that defines an outer periphery of the contact lens, and at least a first lens feature having a predetermined shape and made of a first polymerized Reactive Mixture. The remainder of the lens is made of a second polymerized Reactive Mixture that is different than the first polymerized Reactive Mixture, and that is covalently bonded thereto.

Abstract: This invention describes methods and apparatus for implementing a Convergence Process to Converge a Lens Design wherein a previous DMD Show may be modified for a subsequent Iteration. In preferred embodiments, an Iterative Loop may be initiated during a Convergence Process wherein one or more of various: techniques, modalities, and thickness correction methods may be implemented.

Abstract: Methods and systems for determining control inputs to a manufacturing apparatus to manufacture a product are described. A processor may receive model data including initial state data indicating an initial state of an input material, a set of model control inputs, and target measurement data associated with a target product. The processor may learn a causal predictive model based on the target data. Each state of the causal predictive model may be based on an application of the model control inputs on a previous state of the causal predictive model. The processor may compare a final state of the causal predictive model with the target measurement data to determine a difference. The processor may determine, based on the difference, a set of control inputs to be assigned to one or more controls. The one or more controls may define a design of the manufacturing process of an end product.

Abstract: A Free-form contact lens and method of making the same. The lens includes a posterior optical quality surface having a concave shape, an opposing anterior surface having a convex shape both of which join at a lens edge that defines an outer periphery of the contact lens, and at least a first lens feature having a predetermined shape and made of a first polymerized Reactive Mixture. The remainder of the lens is made of a second polymerized Reactive Mixture that is different than the first polymerized Reactive Mixture, and that is covalently bonded thereto.

Abstract: Methods for manufacturing an ophthalmic lens with an insert using voxel-based lithography techniques, wherein at least a portion of one surface may be free-formed from a reactive mixture are set forth herein. An ophthalmic lens precursor may be formed on a substrate with an arcuate optical quality surface via a source of actinic radiation controllable to cure a definable portion of a volume of reactive mixture, wherein the control may be on a voxel by voxel basis.

Abstract: Methods for manufacturing an ophthalmic lens with an insert using voxel-based lithography techniques, wherein at least a portion of one surface may be free-formed from a reactive mixture are set forth herein. An ophthalmic lens precursor may be formed on a substrate with an arcuate optical quality surface via a source of actinic radiation controllable to cure a definable portion of a volume of reactive mixture, wherein the control may be on a voxel by voxel basis.

Abstract: This invention describes methods and apparatus for implementing a Convergence Process to Converge a Lens Design wherein a previous DMD Show may be modified for a subsequent Iteration. In preferred embodiments, an Iterative Loop may be initiated during a Convergence Process wherein one or more of various: techniques, modalities, and thickness correction methods may be implemented.

Abstract: A contact lens having a lens edge defining an outer periphery of the contact lens, an optic zone positioned within the lens edge designed to provide corrective vision for a patient, a Lens Center having a vertical axis and a horizontal axis passing therethrough, and first and second fiducial indicators present at first and second different locations around the lens edge. The first and second fiducial indicators each include at least one recess into or at least one projection extending outwardly from the lens edge and are different from one another.

Abstract: A Free-form contact lens and method of making the same. The lens includes a posterior optical quality surface having a concave shape, an opposing anterior surface having a convex shape both of which join at a lens edge that defines an outer periphery of the contact lens, and at least a first lens feature having a predetermined shape and made of a first polymerized Reactive Mixture. The remainder of the lens is made of a second polymerized Reactive Mixture that is different than the first polymerized Reactive Mixture, and that is covalently bonded thereto.

Abstract: A Free-form contact lens and method of making the same. The lens includes a posterior optical quality surface having a concave shape, an opposing anterior surface having a convex shape both of which join at a lens edge that defines an outer periphery of the contact lens, and at least a first lens feature having a predetermined shape and made of a first polymerized Reactive Mixture. The remainder of the lens is made of a second polymerized Reactive Mixture that is different than the first polymerized Reactive Mixture, and that is covalently bonded thereto.

Abstract: This invention provides for the fabrication of ophthalmic lenses via the utilization of DMD shows and/or DMD files. More specifically, the use of the DMD shows and/or DMD files to generate lens precursor designs comprising described features to form part of a substructure for the fluid reactive media portion of the lens precursor and wherein the lens precursor can generate particular ophthalmic lens designs in a free-form manner using methods described herein.

Abstract: This invention provides for the fabrication of ophthalmic lenses via the utilization of DMD shows and/or DMD files. More specifically, the use of the DMD shows and/or DMD files to generate lens precursor designs comprising described features to form part of a substructure for the fluid reactive media portion of the lens precursor and wherein the lens precursor can generate particular ophthalmic lens designs in a free-form manner using methods described herein.