Methods for additively manufacturing ophthalmic devices and manufacturing systems configured to perform such methods

Abstract

The present disclosure provides a method for additively manufacturing an ophthalmic device, comprising providing a starting optical element (5) and inkjet printing a complementary optical element (10) onto the starting optical element (5) with at least one inkjet print head (6) having a plurality of nozzles configured to eject a volume of a predetermined material, wherein the inkjet printing comprises tilting the at least one inkjet print head relative to the starting optical element and / or rotating the starting optical element during inkjet printing.

Description

[Technical Field]

[0001] The present disclosure relates to methods for additively manufacturing ophthalmic devices and manufacturing systems configured to perform such methods.

[0002] The present disclosure also relates to a command and control unit including system elements configured to execute a computer program to perform at least some steps of an additive manufacturing method, as well as a manufacturing system comprising such a command and control unit and configured to perform such a method.

[0003] The present disclosure also relates to a computer program comprising instructions configured to perform additive manufacturing of such a method when said computer program is executed by a computer, and a client-server communication interface for transferring at least manufacturing data determined by the computer program performing at least some parts of such a method to a remote computer, wherein the remote computer performs other parts of such a method when said computer program is executed on an instruction and control unit. [Background technology]

[0004] It is known to use additive manufacturing techniques to manufacture ophthalmic devices, such as eyeglass lenses.

[0005] Known methods for additively manufacturing ophthalmic lenses, such as stereolithography and its variations, involve curing and layer-forming steps that are performed sequentially in a manufacturing system that includes a curing device, a layer-forming device, and a build platform positioned relative to a vat filled with a predetermined material.

[0006] For example, each ophthalmic lens is built layer by layer on a build platform that is movable relative to a vat containing a volume of a predetermined material, the build platform is placed in a predetermined position, a curing device including an irradiation source performs a curing step of a first layer of material, and a layer forming device performs a layer forming step such that a new layer of material having a predetermined thickness can be cured by displacing at least the build platform.

[0007] In other words, in such known methods, a curing step is performed on a layer that is liquid for, for example, a plurality of ophthalmic lenses to be manufactured on a build platform, such that the liquid layer is cured and then a layer formation step is performed to form a new liquid layer on the previous cured layer of the plurality of ophthalmic lenses to be manufactured.

[0008] Another method of additive manufacturing can involve sequentially depositing droplets of liquid material and curing them to form layers of material. This method, commonly referred to as 3D printing or inkjet printing, generally controls the shape of the layer by controlling the position and volume of the deposited droplets, but the curing step is usually global. Other additive manufacturing methods can also be used.

[0009] Producing a complete optical lens layer by layer by additive manufacturing can be time consuming in terms of mass production of the article.

[0010] In this regard, so-called "build-over techniques" can be useful to reduce manufacturing time. Such build-over techniques are disclosed, for example, in U.S. Patent Nos. 5,629,997 and 5,729,997, in which at least one complementary optical element is adjacent to a starting optical element by additive manufacturing. [Prior art documents] [Patent documents]

[0011] [Patent Document 1] International Publication No. 2015 / 004383 [Patent Document 2] International Publication No. 2020 / 115061 Summary of the Invention [Problem to be solved by the invention]

[0012] Therefore, there is a need to provide a method for additively manufacturing ophthalmic devices through buildover and inkjet printing. [Means for solving the problem]

[0013] The present disclosure relates to methods for additively manufacturing ophthalmic devices, for example by build-over and inkjet printing, that are easy to perform.

[0014] Accordingly, the present disclosure provides a method for additively manufacturing an ophthalmic device, the method comprising: providing a starting optical element; and inkjet printing a complementary optical element onto the starting optical element with at least one inkjet print head having a plurality of nozzles configured to eject a volume of a predetermined material, wherein the inkjet printing step comprises tilting the at least one inkjet print head and the starting optical element relative to one another and / or rotating the starting optical element during inkjet printing.

[0015] The method according to the present disclosure allows for printing on a given number of starting optical elements multiple complementary optical elements having different geometric characteristics, including diameter or profile.

[0016] In other words, compared to the known solutions mentioned above, the method according to the present disclosure allows printing on a larger surface of a given starting optical element.

[0017] More generally, the methods according to the present disclosure allow the use of 3D inkjet printing techniques to produce quasi-spherical substrates with different geometric properties, including diameter or profile, for multiples that can be equivalent to substrates or "standard" blanks that are easily produced in mass production.

[0018] In other words, any ophthalmic device formed by combining a customized complementary optic with a standard blank or substrate can be printed.

[0019] The method according to the present disclosure therefore makes it possible to carry out a personalized final ophthalmic device based on a standard blank in a particularly convenient way.

[0020] Of course, the substrate or standard blank may have a simple or complex surface, for example a curved and / or convex surface.

[0021] In embodiments in which both tilting the at least one inkjet print head and the starting optical element relative to one another and rotating the starting optical element during inkjet printing are performed, it is also possible to print on a larger number of starting optical elements compared to known methods, and in fact it is therefore possible to print on starting optical elements with different convex curvatures.

[0022] The starting optical element may be formed by the ophthalmic element itself, i.e., a part of the final ophthalmic device equivalent to the blank described above, or by a part intended to be used in the manufacture of the final ophthalmic device, i.e., a mold onto whose surface a complementary optical element is printed and into which the blank is then molded, cast or injected.

[0023] In a variant, the complementary optical element is removed from the mold and then assembled with the substrate or standard blank.

[0024] This is due to one or a combination of rotating the starting optical element and tilting the at least one inkjet printhead relative to the starting optical element.

[0025] In the method according to the present disclosure, the starting optical element can rotate during inkjet printing. The rotational motion can be continuous during the method. The rotational motion is not used to set the starting optical element in a fixed position before performing inkjet printing, but is used to provide rotation of the starting optical element during deposition of droplets of material.

[0026] The tilt of the at least one inkjet printhead and the starting optical member relative to one another can include a tilt of the inkjet printhead relative to the starting optical member, or a tilt of the starting optical member relative to the inkjet printhead, or both.

[0027] Advantageous and convenient features of the present manufacturing method are described below.

[0028] The starting optical element rotates about an axis of rotation and has an upper surface, such as a convex surface, facing upwardly toward at least one inkjet print head, the at least one inkjet print head being tilted relative to the axis of rotation.

[0029] The method comprises determining at least one tilt angle of at least one inkjet print head as a function of at least a given material and / or geometric characteristics of a starting optical element and / or a complementary optical element to be manufactured to obtain an ophthalmic device.

[0030] At least one tilt angle of the at least one inkjet printhead may also be predetermined.

[0031] The inkjet printing step comprises positioning at least one inkjet printhead at a distance value selected from a plurality of distance values ​​from the starting optical element.

[0032] The distance value is selected so that the inkjet printhead can eject droplets onto different working areas on the starting optical element, thus allowing for the use of a larger surface on a given starting optical element.

[0033] The at least one inkjet print head may also be positioned at a predetermined distance value.

[0034] The method includes determining at least one position of at least one inkjet print head relative to the starting optical element as a function of at least a given material and / or geometric characteristics of the starting optical element and / or complementary optical element to be manufactured to obtain an ophthalmic device.

[0035] The distance value is between the minimum height at which a given material can form a droplet and the maximum height at which a droplet of the given material can be accurately deposited on the starting optical element.

[0036] A droplet is considered herein to be a volume of material lacking a tail or satellite.

[0037] The inkjet printing step includes a first sequence in which at least one inkjet print head is tilted and / or positioned at a first position relative to the starting optical element to print a first portion of the complementary optical element on the first portion of the starting optical element, and a second sequence in which at least one inkjet print head is tilted and / or positioned at a second position relative to the starting optical element to print a second portion of the complementary optical element on the second portion of the starting optical element.

[0038] The second portion may be at least partially distinct from the first portion.

[0039] In a variant, the second portion may be at least partially similar to the first portion, such that the droplets ejected during the second sequence are deposited on top of the droplets deposited during the first sequence.

[0040] The inkjet printing step may be performed by a plurality of inkjet printheads, each having a plurality of nozzles, and each tilted and / or positioned at a respective determined position relative to the starting optical member.

[0041] For example, the inkjet printheads may have similar or different tilt angles and may be positioned symmetrically or asymmetrically relative to a plane passing through the axis of rotation of the starting optical element.

[0042] For example, the inkjet printheads may have different tilt angles and may be positioned on the same side of a plane passing through the axis of rotation of the starting optical element.

[0043] For example, the distance values ​​between each inkjet printhead and the starting optical member can be similar or different.

[0044] The method may comprise a step of determining manufacturing settings including at least the tilt angle of at least one inkjet print head and / or operational parameters such as the position and / or printing resolution and / or rotation speed of the starting optical element as a function of a given material and / or the geometric properties of the starting optical element and / or complementary optical element to be manufactured to obtain an ophthalmic device, and / or the optical function of the ophthalmic device to be manufactured.

[0045] The printing resolution has a process resolution, which corresponds to an angular resolution defined as a function of at least the rotational speed of the starting optical element and the nozzle firing frequency, and a printhead resolution, which corresponds to a radial resolution of the printhead, which is defined as a function of at least the number and arrangement of the nozzles.

[0046] A production setup may have several sequences, for each of which some nozzles are activated and some nozzles are deactivated.

[0047] At least some of the sequences may correspond to at least one revolution of the starting optical element, or less than one revolution of the starting optical element.

[0048] According to a second aspect, the present disclosure also provides a command and control unit including system elements configured to execute a computer program to perform at least some of the steps of the additive manufacturing method described above to manufacture an ophthalmic device.

[0049] According to a third aspect, the present disclosure further provides a manufacturing system comprising an inkjet printer comprising at least one inkjet print head having a plurality of nozzles and the command and control unit as described above, the manufacturing system being configured to perform the steps of the additive manufacturing method as described above.

[0050] According to a fourth aspect, the present disclosure also provides a computer program comprising instructions configured to perform at least some of the steps of the additive manufacturing method described above when said computer program is executed by a computer.

[0051] According to a fifth aspect, the present disclosure further provides a client-server communication interface for transferring at least manufacturing data, such as tilt angle and / or rotation speed, determined by a computer program implementing at least some steps of a method for additively manufacturing an ophthalmic device as described above to a remote computer, wherein the remote computer implements other steps of such additive manufacturing method when the computer program is executed on an instruction and control unit.

[0052] The description of the present disclosure now continues with a detailed description of the embodiments shown below, by way of non-limiting examples and with reference to the accompanying drawings. [Brief explanation of the drawings]

[0053] [Figure 1] FIG. 1 is a schematic diagram of a manufacturing system configured to perform a method for additively manufacturing an ophthalmic device. [Figure 2]1 is a schematic diagram of a client-server communication interface comprising a system portion configured to transfer at least one configuration parameter determined by a method according to the present disclosure to a remote data processing system. [Figure 3] 1 is a block diagram illustrating steps in a method for additively manufacturing an ophthalmic device according to the present disclosure. [Figure 4] 1 is a schematic diagram illustrating a method performed according to a first embodiment. [Figure 5] FIG. 4 is a schematic diagram illustrating a method performed according to a second embodiment. [Figure 6] FIG. 4 is a schematic diagram illustrating a method performed according to a second embodiment. [Figure 7] FIG. 6 is a schematic diagram illustrating a method performed according to a variant of the second embodiment. [Figure 8] FIG. 6 is a schematic diagram illustrating a method performed according to a variant of the second embodiment. [Figure 9] FIG. 10 is a schematic diagram illustrating a method performed according to a third embodiment. [Figure 10] FIG. 10 is a schematic diagram illustrating a method performed according to a fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0054] FIG. 1 illustrates schematically a manufacturing system 1 configured to perform a method for additively manufacturing an ophthalmic device 2 .

[0055] In the illustrated embodiment, the manufacturing system 1 is an additive system configured to manufacture the ophthalmic device 2 layer by layer, with each layer 3 being formed by a volume of a predetermined material 11 that is at least partially polymerized and cured.

[0056] In this respect, the manufacturing system 1 comprises an additive unit, also called additive manufacturing module, here formed by an inkjet printer 4 configured to eject a volume of a predetermined material in the form of droplets.

[0057] Certain materials are suitable for manufacturing the ophthalmic device 2, such as liquid resins for making eyeglasses.

[0058] The inkjet printer 4 comprises one or more inkjet printheads 6, each having a number of nozzles from which droplets of a selected material are ejected.

[0059] A droplet is considered herein to be a volume of material lacking a tail or satellite.

[0060] Each print head 6 has a predetermined number of nozzles and a predetermined arrangement thereof. The nozzles can be activated or deactivated.

[0061] The inkjet printer 4 may further comprise an instruction and control unit 7 including system elements configured to execute a computer program including instructions configured to perform at least some steps of an additive manufacturing method according to the present disclosure for manufacturing an ophthalmic device 2.

[0062] The command and control unit 7 may be configured to command and control the printhead 6, in particular the printhead resolution, which corresponds to the radial resolution of the printhead 6, which is defined as a function of at least the number and arrangement of the nozzles.

[0063] The command and control unit 7 may be configured to command and control the activation and / or deactivation of each nozzle and the firing frequency of each nozzle.

[0064] The nozzle firing frequency can be variable or fixed.

[0065] The nozzle firing frequency may depend on at least the geometrical properties of the starting optical element 5, and / or the geometrical properties of the complementary optical element, and / or the rotational speed of the starting optical element, and / or its position, including tilt and radial shift, relative to the axis of rotation of the print head.

[0066] The command and control unit 7 may be configured to command and control the position of the print head 6 .

[0067] The inkjet printer 4 is here arranged on top of the starting optical element 5 and is configured to build on the starting optical element 5 a complementary optical element 10 formed by the layer 3 .

[0068] In other words, the starting optical element 5 may have a top surface, such as a convex surface, facing upwardly towards the print head 6 .

[0069] The command and control unit 7 may be configured to position the print head 6 at a distance value selected from a plurality of distance values ​​from the starting optical element 5 .

[0070] The distance value lies between the minimum height at which a given material can form a droplet and the maximum height at which a droplet of the given material is accurately deposited on the starting optical element 5 .

[0071] The starting optical element 5 can here rotate around a rotation axis R, and the print head 6 and the starting optical element 5 can be tilted relative to each other and / or the print head 6 can be tilted relative to the rotation axis R.

[0072] In this respect, the command and control unit 7 may also be configured to command and control the tilt angle of the print head 6 and the starting optical member 5 relative to each other, as well as the rotation speed of the starting optical member 5 about the rotation axis R.

[0073] In addition, the command and control unit 7 may be configured to command and control the printing resolution of the print head 6, having a process resolution corresponding to an angular resolution defined as a function of at least the rotation speed and nozzle firing frequency of the starting optical element 5, and a print head resolution as defined above.

[0074] For example, the resulting ophthalmic device 2 may be a combination of a complementary optical element 10 and a starting optical element 5, where the starting optical element 5 forms the substrate or standard blank itself.

[0075] In a variant, the starting optical member may be part of a forming device, and the complementary optical member may be built on the forming device, then removed from the starting optical member, and then assembled with a separate standard blank.

[0076] In another variation, the starting optical element may be part of a molding device, a complementary optical element is built onto the part of the molding device, and then a standard blank is molded, cast or injected directly within the molding device and onto the complementary optical element.

[0077] In another variation, the starting optical element may be part of a molding device, and the complementary optical element is built onto the part of the molding device and formed so that it can be mounted directly within the frame of the eyeglasses.

[0078] FIG. 2 shows, for example, a client-server communication interface 24 comprising a so-called supplier side 29 a and another so-called client side 29 b , these two sides communicating via an internet interface 28 .

[0079] The supplier side comprises a server 29a linked to a data processing system or command and control unit 27a of the same type as the command and control unit 7 disclosed in FIG. 1, this server 29a being configured to communicate with an internet interface 28.

[0080] The client side 29b is arranged to communicate with the internet interface 28 and is linked to a data processing system or command and control unit 27b of the same type as that of the supplier side.

[0081] Furthermore, the client-side command and control unit 27b is linked to a manufacturing system 1b of the same type as that of FIG. 1 for manufacturing the ophthalmic devices 2b layer by layer 3b.

[0082] For example, the client-side command and control unit 27b is configured for the user to receive certain parameters relating to the ophthalmic device to be machined, the inkjet printer 4, and the manufacturing method intended to be performed to additively manufacture the ophthalmic device 2b.

[0083] The client-side command and control unit 27b uses the internet 28 and server 29a interface to transmit the received data to the supplier-side command and control unit 27a for determination of production files and operating parameters.

[0084] The supplier's command and control unit 27a executes the computer program it contains to carry out the steps of the method for additively manufacturing ophthalmic devices.

[0085] Using the server 29a and the internet interface 28, the supplier-side command and control unit 27a transmits the manufacturing files and operating parameters to the client-side command and control unit 27b.

[0086] The client-side command and control unit 27b is here configured to execute software for carrying out the other steps of the method for additively manufacturing an ophthalmic device.

[0087] In a variant, the manufacturing system may be located at the supplier's side, such that a command and control unit at the supplier's side determines the manufacturing files and operating parameters and is configured to additively manufacture the ophthalmic device.

[0088] FIG. 3 is a block diagram illustrating the main steps of a manufacturing flow (method) 100 for additively manufacturing an ophthalmic device 2 performed by a manufacturing system 1 as described above.

[0089] The method comprises a step 101 of providing a starting optical element 5 .

[0090] The method may comprise the following steps. - providing the geometric characteristics of the starting optical element 5, - providing the geometric characteristics of a complementary optical element 10 for manufacturing to obtain an ophthalmic device 2, - providing predetermined material parameters, and / or - providing optical functionality of the ophthalmic device 2 to be manufactured.

[0091] The method further comprises a step 102 of rotating the starting optical element 5 .

[0092] The method may also include a step 120 of determining the rotation speed of the starting optical element 5 as a function of at least the given material and / or geometric properties of the starting optical element 5 and / or complementary optical element 10 to be manufactured to obtain the ophthalmic device 2, and / or the optical function of the ophthalmic device 2 to be manufactured.

[0093] The method further comprises a step 103 of tilting the inkjet print head 6 and the starting optical member 5 relative to each other.

[0094] The method may also include a step 130 of determining at least one tilt angle of the inkjet print head 6 as a function of at least the given material and / or geometric characteristics of the starting optical element 5 and / or the complementary optical element 10 to be manufactured to obtain the ophthalmic device 2.

[0095] The tilt of the inkjet print head 6 and the starting optical element 5 relative to each other can include a tilt of the inkjet print head 6 relative to the starting optical element 5, or a tilt of the starting optical element 5 relative to the inkjet print head 6, or both.

[0096] The method further includes step 104 of positioning the inkjet print head 6 at a distance value selected from a plurality of distance values ​​from the starting optical element 5 .

[0097] The method may also include a step 140 of determining at least one position of the inkjet print head 6 relative to the starting optical element 5 as a function of at least the given material and / or geometric characteristics of the starting optical element 5 and / or complementary optical element 10 to be manufactured to obtain the ophthalmic device 2.

[0098] The method further comprises a step 105 of inkjet printing a complementary optical element 10 onto the starting optical element 5 in a build-over mode.

[0099] The method may also comprise a step 150 of determining the printing resolution of the inkjet print head 6 as a function of at least the given material and / or geometrical properties of the starting optical element 5 and / or the complementary optical element 10 to be manufactured to obtain the ophthalmic device 2 and / or the optical functionality of the ophthalmic device 2 to be manufactured. The printing resolution is defined as above.

[0100] In other words, the method may comprise a step of determining manufacturing settings including operational parameters such as the tilt angle of the inkjet print head 6 determined in step 130, and / or the position of the inkjet print head 6 determined in step 140, and / or the printing resolution of the inkjet print head 6 determined in step 150, and / or the rotation speed of the starting optical element 5 determined in step 120.

[0101] It should be noted that the inkjet printing step 105 may comprise a manufacturing setup having one or more sequences.

[0102] For example, the inkjet printing step 105 may include at least a first sequence in which the inkjet print head 6 is tilted and / or positioned at a first position relative to the starting optical element 5 to print a first portion of the complementary optical element 10 onto a first portion of the starting optical element 5, and then at least a second sequence in which the inkjet print head 6 is tilted and / or positioned at a second position relative to the starting optical element 5 to print a second portion of the complementary optical element 10 onto a second portion of the starting optical element 5.

[0103] The second portion may be at least partially distinct from the first portion, or may be at least partially similar.

[0104] The first sequence and the second sequence may be performed sequentially or simultaneously by several inkjet print heads 6 .

[0105] Thus, a production setup may comprise several sequences in which some nozzles are activated and some nozzles are deactivated.

[0106] At least some of the sequences may correspond to at least one revolution of the starting optical element 5 or less than one revolution of the starting optical element 5 .

[0107] Of course, between the two sequences the print head can be displaced radially relative to the axis of rotation of the starting optical element 5 .

[0108] In one embodiment, the two print heads may be positioned at different tilt angles relative to the starting optical member and with a radial shift relative to each other.

[0109] Figure 4 shows a rotating starting optical element 5 and an inkjet print head 6 tilted by a tilt angle Ta relative to the rotation axis of the starting optical element 5 and positioned at a fixed distance from the starting optical element 5 so as to inject material onto the starting optical element 5 to form a layer 3 in order to build a complementary optical element 10 on the starting optical element 5.

[0110] 5 and 6 show a starting optical element 5 configured to rotate an inkjet print head 6 tilted at a tilt angle Ta relative to the axis of rotation of the starting optical element 5 and positioned at a variable distance from the starting optical element 5 to eject material to form a layer 3 to build a complementary optical element 10 on the starting optical element 5. In FIG. 5, the inkjet print head 6 is at a first distance from the starting optical element 5 and forms a first layer, and in FIG. 6, the inkjet print head 6 is at a second distance from the starting optical element 5 that is greater than the first distance and forms a second layer on the starting optical element 5 that is above the first layer.

[0111] The second layer is now added to a portion of the starting optical element that has not yet been layered.

[0112] In a variation, the second layer may be at least partially affixed to a portion of the first layer.

[0113] Thus, Figures 5 and 6 show that by varying the distance, it is possible to inkjet print over a larger area on the starting optical element 5 compared to, for example, having a print head that rotates at a fixed distance from the starting optical element 5 and depositing ink only on the portion of the starting optical element that is within a given distance from the print head.

[0114] 7 and 8 are similar to FIGS. 5 and 6 except that more nozzles of the print head 6 are activated than in FIGS.

[0115] As a result, multiple layers 3 can be formed simultaneously on different portions of the starting optical element 5 .

[0116] In one embodiment, at least one layer may spirally wrap around a portion of itself.

[0117] Figure 7 shows that when the print head 6 is positioned a first distance from the starting optical element 5, a layer 3 is formed on both the lower and upper sides of the starting optical element 5, and Figure 8 shows that when the print head 6 is positioned a second distance from the starting optical element 5, another layer 3 is also formed on both the lower and upper sides of the starting optical element 5.

[0118] In the present disclosure, even if two portions of the layered starting optical element 5 are separated from each other, i.e., not adjacent and not in contact, the printing resolution can take into account any layer already printed at any position and predetermined distance of the starting optical element in order to proceed with the deposition of a subsequent layer of material.

[0119] 7 and 8 therefore show that by doubling the nozzle activation at varying distances, it is possible to inkjet print larger areas and simultaneously in different portions of the starting optical element 5 more quickly.

[0120] In the embodiment of Figure 9, the inkjet printer includes two print heads 6, one of which is inclined by an inclination angle Ta relative to the starting optical element 5, and the other of which is not inclined and is therefore positioned substantially perpendicular to the rotation axis R about which the starting optical element 5 is rotated.

[0121] In the embodiment of Figure 10, the inkjet printer also includes two print heads 6, one of which is inclined by a first tilt angle Ta1 relative to the starting optical element 5, and the other of which is inclined by a second tilt angle Ta2 relative to the starting optical element 5 that is distinct from the first tilt angle Ta1.

[0122] More generally, inkjet printing may be performed by one or more inkjet print heads 6 each having a plurality of nozzles and each tilted and / or positioned at a respective determined position relative to the starting optical element 5.

[0123] For example, the inkjet print heads 6 may have similar or different tilt angles, and may be positioned symmetrically or asymmetrically with respect to a plane passing through the rotation axis R of the starting optical element 5 .

[0124] FIG. 10 shows two print heads 6 asymmetrically, one print head 6 being closer to the axis of rotation R than the other print head 6 .

[0125] In addition, the distance between each inkjet print head 6 and the starting optical member 5 can be similar or different.

[0126] Additionally, the inkjet printheads 6 may have similar or different printhead resolutions.

[0127] In a variation not shown, the inkjet printheads may be arranged symmetrically at similar or different tilt angles.

[0128] In another variation not shown, the inkjet print heads may have different tilt angles and may be located on the same side of a plane passing through the axis of rotation of the starting optical element.

[0129] In another example not shown, at least one inkjet print head may be curved, with the nozzle arrangement adapted to direct droplets onto the starting optical element.

[0130] The method according to the present disclosure allows for printing on a given number of starting optical elements multiple complementary optical elements having different geometric characteristics, including diameter or profile.

[0131] In other words, compared to the known solutions mentioned above, the method according to the present disclosure allows printing on a larger surface of a given starting optical element.

[0132] More generally, the methods according to the present disclosure allow the use of 3D inkjet printing techniques to produce quasi-spherical substrates with different geometric properties, including diameter or profile, for multiples that can be equivalent to substrates or "standard" blanks that are easily produced in mass production.

[0133] In other words, any ophthalmic device formed by combining a customized complementary optic with a standard blank or substrate can be printed.

[0134] The method according to the present disclosure therefore makes it possible to carry out a personalized final ophthalmic device based on a standard blank in a particularly convenient way.

[0135] Of course, the substrate or standard blank may have a simple or complex surface, for example a curved and / or convex and / or pseudo-spherical surface.

[0136] In embodiments in which both tilting at least one inkjet print head and the starting optical element relative to each other and rotating the starting optical element during inkjet printing are performed, it is also possible to print on a larger number of starting optical elements compared to known methods.

[0137] For example, ophthalmic devices with either low optical lower portions or high or very high optical lower portions can be manufactured by buildover and inkjet printing.

[0138] In other words, ophthalmic devices with either low base curvature or high or very high base curvature can be manufactured by build-over and inkjet printing.

[0139] The complementary optical element may be equivalent to a patch on the starting optical element.

[0140] However, in some embodiments, the patch may be manufactured directly onto the starting optical element, as opposed to the patch being manufactured elsewhere and then applied to the starting optical element.

[0141] The starting optical element may be formed by an ophthalmic element, i.e., a part of the final ophthalmic device equivalent to the blank described above, or by a part intended to be used for the manufacture of the final ophthalmic device, i.e., a mold onto whose surface the complementary optical element is printed, into which the blank is then molded, cast or injected. In a variant, the complementary optical element is removed from the mold and then assembled with the standard blank.

[0142] In a variant, the starting optical element can be an ophthalmic element that is an optical element itself but does not have a surface smoothness that matches that of the optical element. The deposition of ink to form the complementary optical element can have properties that allow it to hide the lack of smoothness. The lack of smoothness can be tailored to facilitate the deposition of printing ink to produce the complementary optical element.

[0143] This is due to a combination of rotation of the starting optical element and tilting of at least one inkjet printhead relative to the starting optical element.

[0144] In the method according to the present disclosure, the starting optical element can rotate during inkjet printing. The rotational movement can be continuous during the method, or at least one layer can spirally cover a portion of itself. The rotational movement is not used to set the starting optical element in a fixed position before performing inkjet printing, but is used to provide rotation of the starting optical element during deposition of droplets of material.

[0145] It should be noted that the ophthalmic devices mentioned above may be ophthalmic lenses for eyeglasses or other devices adapted to a wearer and having ophthalmic properties.

[0146] It is also noted that the additive manufacturing method may be carried out according to any existing suitable technology, for example a technology included in the definition given in the reference ISO / ASTM 52900:2021 or corresponding reference.

[0147] More generally, it should be noted that the present disclosure is not limited to the examples described and illustrated.

Claims

1. A method for additively manufacturing an ophthalmic device (2), comprising: Providing (101) a starting optical element (5); Inkjet printing (105) a complementary optical element (10) onto the starting optical element by at least one inkjet printhead (6) having a plurality of nozzles configured to eject a volume of a predetermined material; Equipped with The method, wherein inkjet printing comprises tilting (103) the at least one inkjet print head and the starting optical element relative to each other and / or rotating (102) the starting optical element during inkjet printing.

2. 2. The method of claim 1, wherein the starting optical element (5) rotates about a rotation axis (R) and has an upper surface, such as a convex surface, facing upwardly toward the at least one inkjet print head (6), and the at least one inkjet print head (6) is tilted with respect to the rotation axis.

3. 3. The method of claim 1, further comprising determining (130) at least one tilt angle of the at least one inkjet print head (6) as a function of at least the predetermined material and / or geometric characteristics of the starting optical element (5) and / or the complementary optical element (10) to be manufactured to obtain the ophthalmic device (2).

4. 4. The method of claim 1, wherein inkjet printing comprises positioning the at least one inkjet print head at a distance value selected from a plurality of distance values ​​from the starting optical element.

5. 5. The method of claim 4, comprising determining (140) at least one position of the at least one inkjet print head (6) relative to the starting optical element (5) as a function of at least the predetermined material and / or geometric characteristics of the starting optical element and / or the complementary optical element (10) to be manufactured to obtain the ophthalmic device (2).

6. 6. The method of claim 1, wherein inkjet printing (105) comprises a first sequence in which the at least one inkjet print head (6) is tilted and / or positioned at a first position relative to the starting optical element (5) to print a first portion of the complementary optical element (10) onto the first portion of the starting optical element, and a second sequence in which the at least one inkjet print head is tilted and / or positioned at a second position relative to the starting optical element to print a second portion of the complementary optical element onto the second portion of the starting optical element.

7. The method of claim 6 , wherein the second portion is at least similar to or at least distinct from the first portion.

8. 8. The method according to any one of claims 1 to 7, wherein the inkjet printing (105) is performed by a plurality of inkjet print heads (6), each having a plurality of nozzles and each tilted and / or positioned at a respective determined position relative to the starting optical element (5).

9. 9. The method according to any one of claims 1 to 8, comprising determining manufacturing settings including operational parameters such as the tilt angle and / or position and / or printing resolution of the at least one inkjet print head (6) and / or the rotation speed of the starting optical element (5) as a function of at least the predetermined material and / or the geometrical properties of the starting optical element and / or the complementary optical element (10) to be manufactured to obtain the ophthalmic device (2) and / or the optical function of the ophthalmic device to be manufactured.

10. 10. The method of claim 9, wherein the printing resolution comprises a process resolution, which corresponds to an angular resolution defined as a function of at least the rotation speed of the starting optical element (5) and nozzle firing frequency, and a print head resolution, which corresponds to a radial resolution defined as a function of at least the number and arrangement of the nozzles.

11. 11. The method according to claim 9 or 10, wherein the production setup comprises several sequences, for each of which some nozzles are activated and some nozzles are deactivated, at least some sequences corresponding to at least one revolution of the starting optical element (5) or less than one revolution of the starting optical element.

12. A command and control unit comprising system elements configured to execute a computer program to implement the method according to any one of claims 1 to 11 for manufacturing an ophthalmic device (2).

13. 13. A manufacturing system configured to perform the method, comprising an inkjet printer (4) including at least one inkjet print head (6) having a plurality of nozzles and a command and control unit (7) according to claim 12.

14. A computer program comprising instructions adapted to perform at least part of the method according to any one of claims 1 to 11 when said computer program is executed by a computer.

15. 12. A client-server communication interface for transferring at least manufacturing data, such as tilt angles and / or rotation speeds, determined by a computer program implementing at least a part of a method for additively manufacturing an ophthalmic device (2) according to any one of claims 1 to 11, to a remote computer, wherein said computer program, when executed on an instruction and control unit, causes said remote computer to implement other steps of said method for additive manufacturing.

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