Abstract: Systems and methods for lens creations are disclosed. The method includes initiating light transmission from a light source through a diffuser into a container holding resin and a substrate. The light transmission is performed according to an irradiation pattern wherein each point in the resin is illuminated by at least 10% of the diffuser. This causes a lens to be formed. To achieve this illumination, at least 15% of the diffuser receives light from the light source. Further, a diameter of the diffuser is greater than or equal to a diameter of the substrate. The system performing the methods includes a polymerization apparatus and may include a resin conditioning and reservoir apparatus, a metrology unit, a resin drainage apparatus and an optional postcuring apparatus.

Abstract: Systems and methods for lens creations are disclosed. The method includes initiating light transmission from a light source through a diffuser into a container holding resin and a substrate. The light transmission is performed according to an irradiation pattern wherein each point in the resin is illuminated by at least 10% of the diffuser. This causes a lens to be formed. To achieve this illumination, at least 15% of the diffuser receives light from the light source. Further, a diameter of the diffuser is greater than or equal to a diameter of the substrate. The system performing the methods includes a polymerization apparatus and may include a resin conditioning and reservoir apparatus, a metrology unit, a resin drainage apparatus and an optional postcuring apparatus.

Abstract: Automatic visual inspection (AVI) systems and methods are disclosed for inspecting transmissive lenses using a plurality of camera poses to provide deflectometric measurements using fringe patterns from at least two points of view. Phase and/or modulation visibility values of the deflectometric measurements are measured for two sensitivities of the patterns taken through an inspection area of the lens from the points of view. Defects are detected based on the phase and/or modulation visibility values at a defect location as compared to at the local area. A defect type is classified to be prismatic, transmissive, lenslet or cosmetic based on the phase and/or modulation visibility values. The defect is localized on the front or back surface of the lens based on the phase and modulation visibility values, and a geometry of the lens orientation. The lens can be invalidated based on defect types, numbers, relative positions and locations.

Abstract: Systems and methods for lens creations are disclosed. The method includes initiating light transmission from a light source through a diffuser into a container holding resin and a substrate. The light transmission is performed according to an irradiation pattern wherein each point in the resin is illuminated by at least 10% of the diffuser. This causes a lens to be formed. To achieve this illumination, at least 15% of the diffuser receives light from the light source. Further, a diameter of the diffuser is greater than or equal to a diameter of the substrate. The system performing the methods includes a polymerization apparatus and may include a resin conditioning and reservoir apparatus, a metrology unit, a resin drainage apparatus and an optional postcuring apparatus.

Abstract: Systems and methods for lens creations are disclosed. The method includes initiating light transmission from a light source through a diffuser into a container holding resin and a substrate. The light transmission is performed according to an irradiation pattern wherein each point in the resin is illuminated by at least 10% of the diffuser. This causes a lens to be formed. To achieve this illumination, at least 15% of the diffuser receives light from the light source. Further, a diameter of the diffuser is greater than or equal to a diameter of the substrate. The system performing the methods includes a polymerization apparatus and may include a resin conditioning and reservoir apparatus, a metrology unit, a resin drainage apparatus and an optional postcuring apparatus.

Abstract: Automatic visual inspection (AVI) systems and methods are disclosed for inspecting transmissive lenses using a plurality of camera poses to provide deflectometric measurements using fringe patterns from at least two points of view. Phase and/or modulation visibility values of the deflectometric measurements are measured for two sensitivities of the patterns taken through an inspection area of the lens from the points of view. Defects are detected based on the phase and/or modulation visibility values at a defect location as compared to at the local area. A defect type is classified to be prismatic, transmissive, lenslet or cosmetic based on the phase and/or modulation visibility values. The defect is localized on the front or back surface of the lens based on the phase and modulation visibility values, and a geometry of the lens orientation. The lens can be invalidated based on defect types, numbers, relative positions and locations.

Abstract: Systems and methods for additive manufacturing a homogeneous optical element are disclosed herein. A homogeneous pattern of light is shined on a polymerizable liquid to form each polymerized solid layer of the optical element.

Abstract: Systems and methods for smoothing a lens are disclosed herein. A monomer used to make or augment the lens according to an additive method is deposited on the lens surface to be smoothed. A film or membrane with certain elastic properties is pressed against the layered (stepped) surface, with the monomer in between the lens and the membrane. The pressure of the membrane spreads the monomer over the surface of the lens, filling the spaces between the layered (stepped) surface and the membrane. A curing agent is applied to transition the monomer into a polymer coating matching the curve of the membrane. The membrane is removed, leaving a clean, smooth lens surface.

Abstract: A method that adds material selectively to a lens substrate and is used to produce a customized eyewear lens with optical power that is discernibly different from the optical power of the lens substrate. The method involves obtaining the lens substrate, calculating and generating an added material design to convert the lens substrate's optical power to a desired optical power for the customized eyewear lens, contacting the lens substrate with a bulk source of flowable radiation-polymerizable material, and irradiating the material with radiation that is controlled for wavelength range, energy and spatial distribution to polymerize the radiation-polymerizable material only in a selected area according to the added material design. The method does not require the use of external shaping structures to form the customized lens on the lens substrate, and the added material is integrally bonded to the substrate.

Abstract: An additive processing method is used to produce a customized eyewear lens by selectively building layers of radiation-polymerized material onto a lens substrate that has optical power properties discernibly different from the optical properties of the customized eyewear lens. The method involves obtaining the lens substrate, calculating the modifications needed to convert the lens substrate's properties to the desired set of properties of the customized lens, generating an additive layer design to achieve the calculated modifications, and identifying at least one control point for confirmation or revision of the additive layer design. The method further involves applying liquid layers of radiation-polymerizable material to the lens substrate and irradiating the liquid layers in selected areas with controlled radiation such that the material is only polymerized and the additive layer is only formed in the select areas irradiated, according to the additive layer design.

Abstract: A rewritable and freezable lens and method for manufacturing thereof are disclosed. This lens includes at least one active element that has optical properties that can be written, frozen and rewritten into new values at least twice. Rewritable and freezable lenses comprising active index polymer dispersed liquid crystal materials are disclosed. In-situ re-adaptation of spectacle and contact lenses is possible at the point of sale. In-vivo re-adaptation of intraocular lenses in the doctor's room is feasible, avoiding further surgery.

Abstract: Systems and methods for additive manufacturing a homogeneous optical element are disclosed herein. A homogeneous pattern of light is shined on a polymerizable liquid to form each polymerized solid layer of the optical element.

Abstract: Systems and methods for smoothing a lens are disclosed herein. A monomer used to make or augment the lens according to an additive method is deposited on the lens surface to be smoothed. A film or membrane with certain elastic properties is pressed against the layered (stepped) surface, with the monomer in between the lens and the membrane. The pressure of the membrane spreads the monomer over the surface of the lens, filling the spaces between the layered (stepped) surface and the membrane. A curing agent is applied to transition the monomer into a polymer coating matching the curve of the membrane. The membrane is removed, leaving a clean, smooth lens surface.

Abstract: A rewritable and freezable lens and method for manufacturing thereof are disclosed. This lens includes at least one active element that has optical properties that can be written, frozen and rewritten into new values at least twice. Rewritable and freezable lenses comprising active index polymer dispersed liquid crystal materials are disclosed. In-situ re-adaptation of spectacle and contact lenses is possible at the point of sale. In-vivo re-adaptation of intraocular lenses in the doctor's room is feasible, avoiding further surgery.

Abstract: A method that adds material selectively to a lens substrate and is used to produce a customized eyewear lens with optical power that is discernibly different from the optical power of the lens substrate. The method involves obtaining the lens substrate, calculating and generating an added material design to convert the lens substrate's optical power to a desired optical power for the customized eyewear lens, contacting the lens substrate with a bulk source of flowable radiation-polymerizable material, and irradiating the material with radiation that is controlled for wavelength range, energy and spatial distribution to polymerize the radiation-polymerizable material only in a selected area according to the added material design. The method does not require the use of external shaping structures to form the customized lens on the lens substrate, and the added material is integrally bonded to the substrate.

Abstract: An additive processing method is used to produce a customized eyewear lens by selectively building layers of radiation-polymerized material onto a lens substrate that has optical power properties discernibly different from the optical properties of the customized eyewear lens. The method involves obtaining the lens substrate, calculating the modifications needed to convert the lens substrate's properties to the desired set of properties of the customized lens, generating an additive layer design to achieve the calculated modifications, and identifying at least one control point for confirmation or revision of the additive layer design. The method further involves applying liquid layers of radiation-polymerizable material to the lens substrate and irradiating the liquid layers in selected areas with controlled radiation such that the material is only polymerized and the additive layer is only formed in the select areas irradiated, according to the additive layer design.

Abstract: The present invention is embodied in ophthalmic lenses having a first lens surface that is described by a continuous, gradual increase in optical power that proceeds without inflection points of discontinuities across substantially the entire useable optical area of this lens surface, and an opposite surface of the lens configured to cooperate with the power gradation of the first surface to provide a desired prescription, including at least one stabilized area of optical power. The power gradation of the first surface increases from one edge of the useable area to substantially the opposite edge, and may increase according to linear or non-linear relationships. In another preferred embodiment, the two lens surfaces cooperate to create two stabilized areas of optical power, for a prescription with near-viewing and distance-viewing values.

Abstract: The present invention is embodied in ophthalmic lenses having a first lens surface that is described by a continuous, gradual increase in optical power that proceeds without inflection points of discontinuities across substantially the entire useable optical area of this lens surface, and an opposite surface of the lens configured to cooperate with the power gradation of the first surface to provide a desired prescription, including at least one stabilized area of optical power. The power gradation of the first surface increases from one edge of the useable area to substantially the opposite edge, and may increase according to linear or non-linear relationships. In another preferred embodiment, the two lens surfaces cooperate to create two stabilized areas of optical power, for a prescription with near-viewing and distance-viewing values.