Nanostructured intraocular lens and method for making same

Abstract

Certain aspects provide an intraocular lens (IOL) comprising a monolithic lens body having an anterior nanostructure assembly on an anterior outer surface of the monolithic lens body and a posterior nanostructure assembly on a posterior outer surface of the monolithic lens body, and one or more haptics coupled to the monolithic lens body.

Description

[Technical field]

[0001] The present disclosure relates to nanostructured intraocular lenses and methods for making same. [Background technology]

[0002] The human eye, simply put, functions to provide vision by transmitting light through a clear outer portion called the cornea and focusing an image onto the retina by means of the lens. The quality of the focused image depends on many factors, including the size and shape of the eye and the transparency of the cornea and lens. When age or disease reduces the transparency of the lens, vision is reduced because less light can be transmitted to the retina. Such damage to the eye's lens is medically known as cataracts. The accepted treatment for this condition is to surgically remove the lens and replace its function with an intraocular lens (IOL).

[0003] While existing IOLs and their manufacturing methods and systems may be acceptable, they suffer from several shortcomings. Thus, there is a need for improvements in IOL designs and associated manufacturing techniques for complex optical designs. Summary of the Invention [Means for solving the problem]

[0004] Aspects of the present disclosure provide an intraocular lens (IOL) comprising a monolithic lens body having an anterior nanostructure assembly on an anterior outer surface of the monolithic lens body and a posterior nanostructure assembly on a posterior outer surface of the monolithic lens body, and one or more haptics coupled to the monolithic lens body.

[0005] Aspects of the present disclosure also provide a lens mold for forming an intraocular lens (IOL) by injection molding. The lens mold includes a first mold half having a first inner surface, the first inner surface corresponding to an outer geometric shape of an anterior outer surface of the IOL to be formed, and a second mold half having a second inner surface, the second inner surface corresponding to an outer geometric shape of a posterior outer surface of the IOL to be formed. The first inner surface has a first nanostructured pattern formed thereon, and the second inner surface has a second nanostructured pattern formed thereon.

[0006] Aspects of the present disclosure further provide a method of fabricating an intraocular lens (IOL), the method including fabricating a lens mold including a first mold half and a second mold half, and using the lens mold to fabricate a single monolithic lens body by injection molding and heat curing, the first mold half having a first nanostructured pattern formed on an inner surface thereof and the second mold half having a second nanostructured pattern formed on an inner surface thereof.

[0007] Having briefly summarized the present disclosure above, so that the above-mentioned features of the present disclosure can be understood in detail, the present disclosure may be more particularly described by reference to embodiments, some of which are illustrated in the accompanying drawings. However, it should be noted that the accompanying drawings only illustrate some aspects of the present disclosure, and that the present disclosure may admit of other equally effective embodiments. [Brief description of the drawings]

[0008] [Figure 1A-1C] FIG. 1A shows a top view of an intraocular lens (IOL) according to certain embodiments, FIG. 1B shows a side view of a portion of the IOL of FIG. 1A according to certain embodiments, and FIG. 1C shows an enlarged view of a portion of the IOL of FIG. 1A according to certain embodiments. [Diagram 2] FIG. 2 illustrates exemplary operations for fabricating an IOL having nanostructures, according to certain embodiments. [Figure 3A-3D]3A-3D show various aspects of a lens mold and substrate corresponding to different stages of the operation of FIG. 2, according to certain embodiments. [Figure 4] FIG. 4 illustrates an example operation for forming a mold halve, according to certain embodiments. [Figure 5A-5C] 5A-5C show different aspects of a lens mold and substrate corresponding to various stages of the operation of FIG. 4, according to certain embodiments. [Figure 6] FIG. 6 illustrates an example operation for forming mold halves, according to certain embodiments. [Figure 7A-7F] 7A-7F show different aspects of a lens mold and substrate corresponding to various stages of the operation of FIG. 6, according to certain embodiments. [Figure 8] FIG. 8 illustrates an exemplary system for designing, configuring, and / or forming an IOL, in accordance with certain embodiments. [Figure 9] FIG. 9 illustrates exemplary operations for forming an IOL, according to certain embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] To facilitate understanding, wherever possible, identical reference numerals are used to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further reference.

[0010] Embodiments described herein provide methods and systems for fabricating a unitary, monolithic intraocular lens (IOL) with a nanostructured pattern embossed on an outer surface of the IOL by injection molding (e.g., conventional injection molding). In certain embodiments, the methods and systems include creating a plastic mold having a cavity therein, where a surface of the cavity has the nanostructured pattern, and thus, when manufactured by injection molding using the plastic mold, fabricating an IOL with the nanostructured pattern on the outer surface of the IOL.

[0011] Conventional IOLs with nanostructures on the outer surface of the lens reduce visual impairments and discomforts such as glare, scary eye, and halos because the refractive index and reflectance of the lens can be modified by the nanostructures. However, nanostructures are traditionally fabricated separately, for example by lithography processes, and then attached to an IOL fabricated using conventional molding. The embodiments described herein provide a fabrication process that uses injection molding to fabricate a plastic mold that allows fabricating a single-piece monolithic IOL with a nanostructure pattern embossed on the outer surface of the IOL. Fabricating a single-piece monolithic IOL can reduce processing time and costs. In addition, the embodiments described herein do not require attachment of nanostructures to the IOL, eliminating any concerns associated with nanostructures detaching from the IOL in the human eye.

[0012] Nanostructured IOLs FIG. 1A illustrates a top view of an intraocular lens (IOL) 100, according to certain embodiments. FIG. 1B illustrates a side view of a portion of the IOL 100. FIG. 1C illustrates an enlarged side view of a portion of the IOL 100. The IOL 100 comprises a lens body 102 having an anterior outer surface 102A and a posterior outer surface 102P, and a haptic portion 104 coupled to a peripheral non-optical portion of the lens body 102. It should be noted that the shape and curvature of the lens body 102 are shown for illustrative purposes only, and other shapes and curvatures are within the scope of the present disclosure. For example, the lens body 102 illustrated in FIG. 1B has a biconvex shape. In other examples, the lens body 102 can have a plano-convex, convex-concave, or plano-concave shape.

[0013] The lens body 102 has a diameter φ of about 4.5 mm to about 7.5 mm (e.g., about 6.0 mm). The lens body 102 comprises an anterior nanostructure assembly 106A on the anterior outer surface 102A and a posterior nanostructure assembly 106P on the posterior outer surface 102P. In certain embodiments, the lens body 102 comprises only one of the anterior nanostructure assembly 106A or the posterior nanostructure assembly 106, and the outer surface 102A or 102P on which no nanostructure assembly is formed comprises a diffractive structure that adjusts the refractive index and / or reflectivity of the lens. In certain embodiments, as shown in FIG. 1B, the IOL 100 is a monofocal IOL (having a single focus) without an annular echelette formed on the anterior outer surface 102A or the posterior outer surface 102P. In some other embodiments, IOL 100 is a multifocal IOL (having multiple foci, e.g., bifocal and trifocal) with annular echelettes on anterior outer surface 102A and / or posterior outer surface 102P (not shown). In some other embodiments, IOL 100 is an extended depth of focus (EDOF) IOL (having an elongated focus) with annular echelettes on posterior outer surface 102P (not shown).

[0014] As shown in FIG. 1C, the front nanostructure assembly 106A includes protrusions 108. The rear nanostructure assembly 106P includes similar protrusions 108. The shape, size, and density of the protrusions 108 (e.g., spacing between adjacent protrusions 108) are designed to provide the lens body 102 with a desired refractive index. For example, the protrusions 108 may have a height H of about 30 nm to about 200 nm, a width of about 30 nm to about 300 nm, and a spacing between adjacent protrusions 108 of about 30 nm to about 300 nm. The nanostructure assemblies 106A, 106P may further reduce the reflectivity by about 10% to about 90% compared to a lens body without a nanostructure assembly on its front or rear outer surface. In certain embodiments, as shown in FIG. 1B, the nanostructure assemblies 106A, 106P completely cover the front and rear outer surfaces 102A, 102P, respectively. However, in some other embodiments, the nanostructure assemblies 106A, 106P only partially cover the front exterior surface 102A and the rear exterior surface 102P, respectively.

[0015] The lens body 102 and nanostructure assemblies 106A, 106P may be fabricated as a single monolithic piece using clear, flexible, biocompatible lens-forming materials such as modified poly(methyl methacrylate) (PMMA), modified PMMA hydrogel, hydroxyethyl methacrylate (HEMA), PVA hydrogel, other silicone polymer materials, hydrophobic acrylic polymer materials, such as AcrySof® and Clareon® available from Alcon, Inc. of Fort Worth, Texas. The lens body 102 may have a refractive index, n, of about 1.49 to about 1.56.

[0016] In certain embodiments, the anterior exterior surface 102A and / or the posterior exterior surface 102P of the lens body 102 may be fabricated from a biocompatible material (e.g., polymethylmethacrylate (PMMA)) that is stiffer than the material of the remainder of the lens body 102.

[0017] The haptic portion 104 includes radially extending struts (also referred to as "haptics") 104A and 104B. The haptics 104A and 104B may be fabricated from a biocompatible material such as PMMA. The haptics 104A and 104B are bonded (e.g., glued or welded) to a peripheral portion of the lens body 102 or are molded with a portion of the lens body 102 such that they extend outwardly from the lens body 102 to engage the peripheral wall of the eye's capsular bag to maintain the lens body 102 in a desired position on the eye. The haptics 104A and 104B typically have radially outer ends that define arcuate terminal portions. The terminal portions of the haptics 104A and 104B may be separated by a length L of about 6 mm to about 22 mm (e.g., about 13 mm). Haptics 104A and 104B have a particular length such that the end portions generate a slight engagement pressure when in contact with the equatorial region of the capsular bag after insertion. Although FIG. 1A shows one example configuration of haptics 104A and 104B, any plate haptics or other types of haptics may be used.

[0018] Fabrication of nanostructured IOLs Figure 2 illustrates an exemplary operation 200 for fabricating an IOL having nanostructures. Figures 3A, 3B, 3C, and 3D illustrate various aspects of a lens mold and substrate that correspond to different stages of operation 200. As such, Figures 2, 3A, 3B, 3C, and 3D are discussed together.

[0019] In step 210, a nanostructured pattern 302 is formed on a substrate 304 by standard micro / nano fabrication methods, as shown in the isometric view of FIG. 3A and the cross-sectional view of FIG. 3B. For example, a photolithography process is first performed to spin-coat photoresist on the substrate 304, and selected areas of the photoresist are exposed to light and developed. The pattern in the photoresist is then transferred to the substrate 304 by reactive ion etching. The remaining photoresist is then removed by plasma overetching. The nanostructured pattern 302 may span an area of ​​about 7 mm by about 7 mm of the substrate 304 and may comprise an array of trenches 306 cut into the substrate 304 with a height of about 30 nm to about 200 nm, a width of about 30 nm to about 300 nm, and a spacing between adjacent trenches of about 30 nm to about 300 nm.

[0020] As used herein, the term "substrate" refers to a layer of material that serves as a basis for subsequent processing operations and includes a surface to be cleaned. For example, the substrate may include glass or one or more conductive metals such as nickel, titanium, platinum, molybdenum, rhenium, osmium, chromium, iron, aluminum, copper, tungsten, or combinations thereof. The substrate may also include one or more materials including silicon, including materials related to group IV or group III-V, including compounds such as Si, polysilicon, amorphous silicon, silicon nitride, silicon oxynitride, silicon oxide, Ge, SiGe, GaAs, InP, InAs, GaAs, GaP, InGaAs, InGaAsP, GaSb, InSb, or combinations thereof. Furthermore, the substrate may also include dielectric materials such as silicon dioxide, organosilicates, and carbon-doped silicon oxide. Furthermore, the substrate may include any other materials such as metal nitrides, metal oxides, and metal alloys depending on the application.

[0021] Furthermore, the substrate is not limited to any particular size or shape. The substrate can be a circular wafer having a diameter of 200 mm, a diameter of 300 mm, a diameter of 450 mm, or other diameter. The substrate can also be any polygonal, square, rectangular, curved, or other non-circular workpiece, such as a polygonal glass, plastic substrate.

[0022] In step 220, a lens mold 308 is fabricated that replicates the nanostructure pattern 302 on the substrate 304, as shown in cross-sectional view in FIG. 3C. The lens mold 308 may be formed of a plastic material, such as polypropylene (PP) or polycarbonate (PC). As shown in FIG. 3C, the lens mold 308 includes a first mold half 310 and a second mold half 312. The first and second mold halves 310, 312 are coupled together (e.g., by being held together using a press fit, by one or more snaps or other retainers (not shown) attached to the mold halves 310, 312 or integrally formed with the mold halves 310, 312) to form a cavity 314 between the first and second mold halves 310, 312. Each mold half 310, 312 defines an inner surface 310A, 312P that corresponds to the desired exterior geometry of the front exterior surface 102A and the rear exterior surface 102P, respectively, of the lens body 102. In the example shown in Figure 3C, each mold half 310, 312 defines a concave inner surface that forms a biconvex lens body 102.

[0023] A nanostructured pattern 316 that replicates the nanostructured pattern 302 on the substrate 304 is formed on the inner surface 310A, 312P of each mold half 310, 312 to form nanostructure assemblies 106A, 106P on the front and rear outer surfaces 102A, 102P, respectively, of the lens body 102. For example, the nanostructured pattern 316 may comprise protrusions having a height of about 30 nm to about 200 nm, a width of about 30 nm to about 300 nm, and a spacing between adjacent protrusions of about 30 nm to about 300 nm.

[0024] In some embodiments, each mold half 310, 312 having the nanostructured pattern 316 is fabricated by depositing mold material directly onto a substrate using a focused ion beam, as described below in connection with operation 400. In some other embodiments, each mold half 310, 312 having the nanostructured pattern 316 is fabricated by a soft lithography process, as described below in connection with operation 600.

[0025] In step 230, the lens body 102 having nanostructure assemblies 106A, 106P is formed as a single monolithic piece by injection molding and heat curing using a lens mold 308. First, a liquid lens-forming material, such as a prepolymer, is injected into the cavity 314 of the lens mold 308 (e.g., through opening 320 and through fill needle 318) to a level sufficient to create the lens body 102 of the desired geometric shape. In certain embodiments, the prepolymer is a monomer, polymer, or polyvinyl alcohol (PVA) hydrogel.

[0026] The cavity 314 may be evacuated through a vent needle 322 located at an opening 324 that is open to atmosphere or connected to a vacuum source such as a low pressure plenum (not shown). The lens-forming material in the lens mold 308 is then cured by polymerizing or crosslinking the prepolymer (e.g., thermal radiation) through the application of light (e.g., UV light) or heat to form a solid lens body 102. The solid lens body 102 is then removed from the lens mold 308.

[0027] Figure 4 illustrates an exemplary operation 400 (i.e., step 220) of forming each mold halve 310, 312 by a focused ion beam (FIB) assisted chemical vapor deposition (CVD) process. Figures 5A, 5B, and 5C illustrate aspects of the lens mold and substrate corresponding to different stages of operation 400. As such, Figures 4, 5A, 5B, and 5C are discussed together.

[0028] In step 410, as shown in FIG. 5A, a mold forming material precursor 502 is sprayed from a precursor gas source 504 onto the substrate 304 on which the nanostructure pattern 302 is formed. To fabricate a polypropylene (PP) lens mold 308, the mold forming material precursor may be a hydroxyl-containing polypropylene (PP) precursor, such as isotactic polypropylene graft copolymer, isotactic [polypropylene-graft-poly(methyl methacrylate)] (i-PP-g-PMMA), and isotactic [polypropylene-graft-polystyrene] (i-PP-g-PS). The mold forming material precursor may be a polycarbonate (PC) precursor containing monomer bisphenol A (BPA). The mold forming material precursor 502 may adhere to the surface of the substrate 304 and the inner wall of the trench 306.

[0029] In step 420, the substrate 304 is scanned by a focused ion beam 506. In a typical FIB system, gallium ions are used to provide the ion beam, although other ions and ion sources, such as multicusp or other plasma ion sources, can be used. The ion beam 506 can break down the mold forming material precursor 502 into smaller distinct components, including volatile components (not shown) and non-volatile components 508. The non-volatile components remain on the substrate 304, while the volatile components are removed by a pumping system (not shown).

[0030] By continuous supply of mold forming material precursor 502 from a precursor gas source 504 (step 410) and ion beam irradiation (step 420), the mold forming material, for example, a polypropylene (PP) precursor or a polycarbonate (PC) precursor, can be deposited on desired areas of the substrate 304 containing the nanostructured pattern 302 to form a mold 510 that replicates the nanostructured pattern 302 on the substrate 304. This mold 510 can be used as the mold halves 310, 312 having the nanostructured pattern 316 (as shown in FIGS. 3C and 3D ).

[0031] FIG 6 illustrates an exemplary operation 600 (i.e., step 220) of forming each mold half 310, 312 by a soft lithography process. Soft lithography can process a variety of elastomeric materials (i.e., mechanically soft materials), such as polymers, gels, and organic monolayers. FIG 7A, FIG 7B, FIG 7C, FIG 7D, FIG 7E, and FIG 7F illustrate aspects of a lens mold and substrate corresponding to different stages of various stages of operation 600. Therefore, FIG 6, FIG 7A, FIG 7B, FIG 7C, FIG 7D, FIG 7E, and FIG 7F are described together.

[0032] In step 610, an elastomeric film (hereafter referred to as a "replica mold") 702 is cast on the substrate 304 having the nanostructured pattern 302 formed thereon, as shown in FIG. 7A. The replica mold 702 may be formed of a thin flexible polymer such as poly(dimethylsiloxane) (PDMS). In the casting process, liquid PDMS may be mixed with a crosslinking agent, poured onto the substrate 304, and heated at an elevated temperature of about 250° C. to about 350° C. to cure and crosslink the PDMS to form the replica mold. The replica mold 702 may have a thickness between about 200 μm to 500 μm. The replica mold 702 has protrusions 704 that replicate the nanostructured pattern 302 on the substrate 304. The protrusions 704 may have a height of about 30 nm to about 200 nm, a width of about 30 nm to about 300 nm, and a spacing between adjacent trenches of about 30 nm to about 300 nm. After casting, the replica mold 702 is removed from the substrate 304 .

[0033] In step 620, as shown in Figure 7B, a layer of photoresist 706 is spin-coated onto the curved surfaces 708 of the posts 710. The curved surfaces 708 correspond to the geometric shape of the outer surfaces 102A, 102P of the lens body 102. The photoresist 706 may be formed of a polymeric material such as polymethylmethacrylate (PMMA) and copolymers based on methylmethacrylate and methacrylic acid. The posts 710 may be formed of a material such as epoxy.

[0034] In step 630, a photomask is formed that is used to pattern the underlying photoresist 706 in the subsequent patterning step 640. To form the photomask, the replica mold 702 is placed on the photoresist 706 and patterned, as shown in FIG. 7C. The placement of the replica mold 702 on the photoresist 706 may be performed under vacuum to create suction between the replica mold 702 and the photoresist 706. Additionally, the replica mold 702 may be patterned using electron beam lithography (also called "e-beam lithography" or "EPL") by removing portions 712 of the replica mold 702 that are between adjacent protrusions 704. The patterned replica mold 702 with protrusions 704 is used as a photomask in the patterning step 640, as described below.

[0035] In step 640, a patterned photoresist 706P is formed, which is used to pattern the curved surface 708 underlying the post 710 in the subsequent patterning step 650, as shown in FIG. 7D. To form the patterned photoresist 706P, the photoresist 706 is patterned by photolithography using the photomask (patterned replica mold 702 having protrusions 704) formed in step 630. In the photolithography process, the photoresist 706 with the replica mold 702 disposed thereon is exposed to ultraviolet (UV) light, developed, and hardened. The patterned replica mold 702 is then removed. The patterned photoresist 706P is used in the patterning step 650, as described below.

[0036] In step 650, the curved surfaces 708 of the posts 710 are patterned by anisotropic etching, such as plasma dry etching, using the patterned photoresist 706P as a mask to form a nanostructure pattern 714, as shown in FIG. 7E.

[0037] In step 660, a mold forming material precursor is sprayed onto the nanostructured pattern 714 on the curved surfaces 708 of the posts 710 and cured to form a mold 716 that replicates the nanostructured pattern 302 on the substrate. This mold 716 can be used as the mold halves 310, 312 having the nanostructured pattern 316 (as shown in Figures 3C and 3D).

[0038] A system for designing IOLs 8 illustrates an exemplary system 800 for designing, constructing, and / or forming an IOL 100. As illustrated, system 800 includes, but is not limited to, a control module 802, a user interface display 804, an interconnect 806, an output device 808, and at least one I / O device interface 810, which may enable connection of various I / O devices (e.g., a keyboard, a display, a mouse device, a pen input, etc.) to system 800.

[0039] The control module 802 includes a central processing unit (CPU) 812, a memory 814, and storage 816. The CPU 812 may read and execute programming instructions stored in the memory 814. Similarly, the CPU 812 may read and store application data resident in the memory 814. The interconnect 806 transmits programming instructions and application data between the CPU 812, the I / O device interface 810, the user interface display 804, the memory 814, the storage 816, the output devices 808, etc. The CPU 812 may represent a single CPU, multiple CPUs, a single CPU with multiple processing cores, etc. Additionally, in certain embodiments, the memory 814 represents a volatile memory, such as a random access memory. Furthermore, in certain embodiments, the storage 816 may be a non-volatile memory, such as a disk drive, a solid state drive, or a collection of storage devices distributed across multiple storage systems.

[0040] As shown, the storage 816 includes input parameters 818. The input parameters 818 include a lens base power and a desired value of the refractive index of the lens body. The memory 814 includes a calculation module 820 that calculates control parameters such as the configuration (e.g., shape, size, and density) of the nanostructure assemblies 106A, 106P. In addition, the memory 814 includes input parameters 822.

[0041] In certain embodiments, the input parameters 822 correspond to the input parameters 818, or at least a subset thereof. In such embodiments, during calculation of the control parameters, the input parameters 822 are retrieved from the storage 816 and executed in the memory 814. In such examples, the calculation module 820 includes executable instructions (e.g., including one or more of the formulas described herein) for calculating the control parameters based on the input parameters 822. In certain other embodiments, the input parameters 822 correspond to parameters received from a user through the user interface display 804. In such embodiments, the calculation module 820 includes executable instructions for calculating the control parameters based on information received from the user interface display 804.

[0042] In certain embodiments, the calculated control parameters are output via output device 808 to a lens manufacturing system configured to receive the control parameters and form a lens in response. In certain other embodiments, system 800 itself represents at least a portion of a lens manufacturing system. In such embodiments, control module 802 then causes hardware components (not shown) of system 800 to form a lens in accordance with the control parameters, per operation 200 described above.

[0043] How the IOL is created 9 illustrates exemplary operations 900 for forming IOL 100. In some embodiments, step 910 of operations 900 is performed by one system (e.g., system 800), while step 920 is performed by a lens manufacturing system. In some other embodiments, both steps 910 and 920 are performed by a lens manufacturing system.

[0044] In step 910, control parameters such as the configuration (e.g., shape, size, and density) of the nanostructure assemblies 106A, 106P are calculated based on the input parameters (e.g., the lens base power and the desired value of the refractive index of the lens body). The calculations performed in step 910 are based on one or more of the embodiments including the formulas described herein.

[0045] In step 920, an IOL (e.g., IOL 100) based on the calculated control parameters, such as the configuration (e.g., shape, size, and density) of the nanostructure assemblies 106A, 106P, is formed according to operation 200 above using suitable methods, systems, and equipment typically used in the manufacture of lenses, as known to those of skill in the art.

[0046] The embodiments described herein provide a method and system for producing a plastic mold that allows for the production of a single-piece monolithic IOL with a nanostructured pattern embossed on its outer surface using injection molding. Thus, the techniques described herein for producing a monolithic lens structure with a nanostructured pattern embossed on its outer surface simplify the conventional manufacturing process. As discussed, the conventional manufacturing process involves separately producing a nanostructured pattern and attaching the nanostructured pattern to the outer surface of the IOL, which increases the complexity and manufacturing costs. Furthermore, any risk associated with nanostructures detaching from the IOL in the human eye is eliminated or at least reduced in a monolithic lens structure with a nanostructured pattern embossed on its outer surface.

[0047] While the forgoing is directed to embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope of the disclosure, which scope is determined by the claims that follow.

Claims

1. a monolithic lens body having a front nanostructure assembly on a front outer surface of the monolithic lens body and a rear nanostructure assembly on a rear outer surface of the monolithic lens body; one or more haptics coupled to the monolithic lens body; An intraocular lens (IOL).

2. The IOL of claim 1 , wherein the monolithic lens body comprises a biocompatible material.

3. The IOL of claim 1 , wherein each of said anterior nanostructure assembly and said posterior nanostructure assembly comprises a plurality of protrusions having a height of 30 nm to 200 nm, a width of 30 nm to 300 nm, and a spacing between adjacent protrusions of 30 nm to 300 nm.

4. The IOL of claim 1 , wherein the monolithic lens body has a refractive index between 1.49 and 1.

56.

5. 2. The IOL of claim 1, wherein the anterior nanostructure assembly and the posterior nanostructure assembly are configured to reduce the reflectivity of the monolithic lens body by 10% to 90% compared to a lens body not having a nanostructure assembly on the anterior or posterior outer surfaces.

6. a first mold half having a first inner surface, said first inner surface corresponding to an exterior geometry of an outer anterior surface of an IOL to be formed; a second mold half having a second inner surface, the second inner surface corresponding to an exterior geometry of an outer posterior surface of the IOL to be formed; A lens mold for forming an intraocular lens (IOL) by injection molding, comprising: the first inner surface having a first nanostructure pattern formed thereon; A lens mold, the second inner surface having a second nanostructure pattern formed thereon.

7. The lens mold of claim 6 , wherein the first mold half and the second mold half each comprise a plastic material.

8. 7. The lens mold of claim 6, wherein each of the first nanostructured pattern and the second nanostructured pattern comprises a plurality of protrusions having a height between 30 nm and 200 nm, a width between 30 nm and 300 nm, and a spacing between adjacent protrusions between 30 nm and 300 nm.

9. Fabricating a lens mold including a first mold half and a second mold half, the first mold half having a first nanostructured pattern formed on an inner surface of the first mold half and the second mold half having a second nanostructured pattern formed on an inner surface of the second mold half; using said lens mold to fabricate a single monolithic lens body by injection molding and heat curing; A method for making an intraocular lens (IOL), comprising:

10. The method of claim 9 , wherein the first mold half and the second mold half each comprise a plastic material.

11. said fabricating said lens mold Spraying a mold forming material precursor onto the substrate having the nanostructure pattern formed thereon; scanning the substrate with a focused ion beam; 10. The method of claim 9, comprising:

12. 12. The method of claim 11, wherein the nanostructured pattern formed on the substrate spans an area of ​​7 mm by 7 mm and comprises an array of trenches having a height of 30 nm to 200 nm, a width of 30 nm to 300 nm, and a spacing between adjacent trenches of 30 nm to 300 nm.

13. The method of claim 11 , wherein the mold forming material precursor comprises a hydroxyl-containing polypropylene (PP) precursor.

14. said fabricating said lens mold casting a replica mold onto a substrate having a nanostructure pattern formed thereon, the replica mold having a plurality of protrusions; spin-coating a layer of photoresist onto the surfaces of the posts; placing the replica mold on the layer of photoresist; patterning the layer of photoresist by photolithography using the replica mold as a mask; patterning the surfaces of the posts by plasma dry etching using the patterned layer of photoresist as a mask; spraying a mold forming material precursor onto the patterned surfaces of the posts and curing the mold forming material precursor; 10. The method of claim 9, comprising:

15. 15. The method of claim 14, wherein the nanostructured pattern formed on the substrate spans an area of ​​7 mm by 7 mm and comprises an array of trenches having a height of 30 nm to 200 nm, a width of 30 nm to 300 nm, and a spacing between adjacent trenches of 30 nm to 300 nm.

16. The method of claim 14 , wherein the replica mold comprises poly(dimethylsiloxane) (PDMS).

17. 15. The method of claim 14, wherein the plurality of protrusions have a height of 30 nm to 200 nm, a width of 30 nm to 300 nm, and a spacing between adjacent trenches of 30 nm to 300 nm.

18. removing portions of the replica mold between adjacent protrusions of the plurality of protrusions by electron beam lithography after said disposing said replica mold on said layer of photoresist. The method of claim 14 further comprising:

19. The method of claim 14, wherein the mold forming material precursor comprises a hydroxyl-containing polypropylene (PP) precursor.

20. The method of claim 14 , wherein the posts comprise epoxy.

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