Optical lens, optical component, and method for manufacturing optical component

Abstract

A computer-readable medium for storing apparatus, methods, and instructions for producing optical lens bodies by sustained tank polymerization. The method may include the steps of projecting radiation into a resin, pulling a gel body away from a projector providing radiation, and controlling the thickness of a pre-gelled zone extending from the resin to the gel body, and the apparatus may be used for this purpose. The controlling step may include receiving a thickness control value. The controlling step may include setting a tensile ratio and obtaining a thickness corresponding to the thickness control value. The controlling step may include setting the radiation intensity corresponding to the thickness control value. The controlling step may include receiving a thickness control value, setting a tensile ratio and radiation intensity, and obtaining a thickness corresponding to the thickness control value. The settings may be based on the resin activation energy.

Description

[Technical Field]

[0001] The technologies disclosed herein relate to optical lenses, and more specifically, to optical lenses and optical components produced by sustained tank polymerization, and preferably to methods for producing optical lenses and optical components via sustained tank polymerization. [Background technology]

[0002] In conventional applications of photopolymerization-based 3D printing, generally referred to as tank polymerization, a layer-by-layer process is used. In this process, small layers of resin are cured and then moved away from the contact point, allowing subsequent layers of resin to cure. Layers may be added in either a top-down or bottom-up manner. In the top-down method, a cured layer of resin is produced by irradiating the surface of the resin liquid with polymerization light, then lowering the layer deeper into the resin liquid, exposing the uncured resin to the surface. In the bottom-up method, a cured layer is produced by irradiating the resin liquid through a window at the bottom of the resin liquid, lifting the layer out of the liquid tank, and exposing the uncured resin to the window. The shape of the printed part is determined by the area and shape of energy exposure from the polymerization light. The printed part can be constructed by separating the printed part from the area of ​​energy exposure, or by printing an interface and curing the printed part in a third dimension. The bottom-up method has several technical advantages over the top-down method, such as the ability to more precisely control the resin layer thickness.

[0003] Developments in the field of tank polymerization have enabled the creation of additive techniques and methods with various advantages. One category of tank polymerization is digital light processing (DLP), which utilizes a projector or array of projectors to trigger polymerization over a large area of ​​resin at once. Further advances in the field of DLP 3D printing have enabled the development of sustained printing techniques, which can allow DLP printers to produce articles at significantly faster rates. One of these techniques is known as high-area high-speed printing (HARP), which utilizes a liquid interface layer between the resin in the tank and a window through which a projector emits light into the resin. The interface layer present in HARP technology provides both a method for reducing adhesion and temperature control of the exothermic polymerization reaction of the resin, enabling sustained bottom-up tank polymerization. Sustained 3D printing capability allows for increased printing speed and mechanical properties that would otherwise be unavailable in conventional layers through layered techniques. The sustained capability of modern 3D printing has the potential to generate significant advances in various fields.

[0004] One area where sustained 3D printing can offer unique benefits is the field of optical lens production. Conventional optical lens production for eyeglasses involves producing optical lenses from large, pre-fabricated lens blanks. These lens blanks are typically produced by classical manufacturing techniques, including injection molding or casting, and they are constructed from optically transparent, high-refractive-index materials such as polycarbonate or glass. The lens blanks are typically produced to have a specific front curvature, and the remainder of the blank then undergoes the necessary processing to be customized and fitted for a specific frame. The lens blanks are typically constructed from either thermosetting plastics, which form chemical bonds and retain their shape after curing under heat, or thermoplastics, which can be melted under high heat and re-cured. These lens blanks are fixed to a support structure and undergo grinding, molding, polishing, coating, etching, coloring, rimming, and equivalent processes, with the final result being an optically functional lens that can be fitted into a desired frame to produce a pair of eyeglasses. Ophthalmic lenses are used to correct various vision-related medical conditions. They are a form of optical lens with a certain shape, structure, and material, which, when customized for a specific user, enables vision correction. This manufacturing process requires lens manufacturers to maintain large inventories at once, as many different pre-fabricated lens raw materials must be available as needed to account for the significant differences in optical lens requirements. In addition, these raw materials are typically much larger than the final optical lens, and processing these raw materials results in a large amount of waste. 3D printing can address some of these issues. However, conventional layer-by-layer techniques struggle to produce lenses with the required optical properties. Continuous 3D printing can address these issues and can enable further advancements in optical lens development, while also having the ability to manufacture these lenses at a much faster rate than conventional 3D printing techniques.In addition, continuous vat polymerization is capable of producing several lenses and associated products that are completely inaccessible to conventional manufacturing techniques.

[0005] As described above, one of the most common uses of optical lenses is their use in eyeglasses, and more specifically, their use in ophthalmic eyeglasses. Ophthalmic lenses are, by nature, corrective and are used to modify the image perceived by the eye and to compensate for vision disorders. The most common vision disorders are myopia and hyperopia, i.e., the states where near objects are difficult to see and far objects are difficult to see. These conditions occur because the image produced by the human eye's lens focuses at a point in front of or behind the retina, respectively. Appropriately prescribed ophthalmic lenses adjust the point, called the focal point, where the image focuses, to correct vision problems and compensate for problems with the human eye's lens and its distance from the retina. Another common vision disorder is astigmatism, which occurs when the surface of the lens, the cornea, or both are not smooth. This results in visual distortion streaks and is corrected via a lens that compensates for this non-uniform curvature. These problems are very common, but each person who requires corrective ophthalmic lenses has a unique need to compensate for their individual vision problems. 3D printing can be positioned as a manufacturing process for producing ophthalmic lenses because each lens can be manufactured with the ophthalmic correction required in mind. Continuous 3D printing, in turn, can overcome the challenges that the layer-by-layer technique has when manufacturing high-quality optical lenses.

Summary of the Invention

Means for Solving the Problems

[0006] An apparatus, a method, and a computer-readable medium storing instructions for producing an optical lens body by continuous slot overlap. The method may include projecting pixelated radiation into a resin, pulling a gel body away from a projector that provides the radiation, and controlling beam characteristics of each pixel in the pixelated radiation, and the apparatus may be used therefor.

Brief Description of the Drawings

[0007] The objects and advantages of the present invention will become apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which like reference characters refer to like parts throughout.

[0008] [Figure 1] FIG. 1 schematically shows an illustrative apparatus according to the principles of the present invention.

[0009] [Figure 2A] FIG. 2A schematically shows an illustrative apparatus according to the principles of the present invention.

[0010] [Figure 2B] FIG. 2B schematically shows an illustrative apparatus according to the principles of the present invention.

[0011] [Figure 3] FIG. 3 schematically shows an illustrative apparatus according to the principles of the present invention.

[0012] [Figure 4] FIG. 4 schematically shows an illustrative apparatus according to the principles of the present invention.

[0013] [Figure 5] FIG. 5 schematically shows an illustrative apparatus according to the principles of the present invention.

[0014] [Figure 6] FIG. 6 schematically shows an illustrative apparatus according to the principles of the present invention.

[0015] [Figure 7] Figure 7 illustrates the principle of the present invention.

[0016] [Figure 8] Figure 8 illustrates the principle of the present invention.

[0017] [Figure 9] Figure 9 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0018] [Figure 10] Figure 10 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0019] [Figure 11] Figure 11 schematically shows an illustrative apparatus based on the principle of the present invention.

[0020] [Figure 12] Figure 12 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0021] [Figure 13] Figure 13 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0022] [Figure 14] Figure 14 shows the steps of an illustrative process according to the principle of the present invention.

[0023] [Figure 15] Figure 15 shows the steps of an illustrative process according to the principle of the present invention.

[0024] [Figure 16] Figure 16 schematically illustrates the conditions within the apparatus according to the present invention.

[0025] [Figure 17] Figure 17 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0026] [Figure 18] Figure 18 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0027] [Figure 19] Figure 19 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0028] [Figure 20] Figure 20 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0029] [Figure 21] Figure 21 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0030] [Figure 22] Figure 22 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0031] [Figure 23] Figure 23 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0032] [Figure 24] Figure 24 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0033] [Figure 25] Figure 25 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0034] [Figure 26] Figure 26 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0035] [Figure 27] Figure 27 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0036] [Figure 28]Figure 28 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0037] [Figure 29] Figure 29 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0038] [Figure 30] Figure 30 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0039] [Figure 31] Figure 31 schematically illustrates an illustrative apparatus based on the principle of the present invention.

[0040] [Figure 32] Figure 32 schematically illustrates illustrative information based on the principle of the present invention.

[0041] [Figure 33] Figure 33 schematically illustrates illustrative information based on the principle of the present invention.

[0042] [Figure 34] Figure 34 schematically illustrates illustrative information based on the principle of the present invention.

[0043] [Figure 35] Figure 35 schematically illustrates illustrative information based on the principle of the present invention. [Modes for carrying out the invention]

[0044] Detailed explanation While the present invention may accept many different embodiments, its specific exemplary embodiments are shown in the drawings and described in detail herein. It should be understood that this disclosure is intended to illustrate the principles of the present invention and is not intended to limit the invention to the specific embodiments shown. In this regard, before describing in detail at least one embodiment consistent with the present invention, it should be understood that the present invention is not limited in its use to the structural and arrangement details of its components as described above and below or described in the examples. Methods and apparatus consistent with the present invention may also have other embodiments and are practiced and implemented in various ways. Furthermore, it should be understood that the terminology and technical terms used herein are for illustrative purposes only and should not be considered limiting.

[0045] The techniques described herein relate to optical lenses and optical components, preferably manufactured via sustained DLP tank polymerization 3D printing, and preferably to methods for producing optical lenses and optical lens precursors via sustained DLP tank polymerization. The techniques described herein also relate to software for controlling a sustained DLP tank polymerization device to implement a method for producing optical lenses and optical precursors. For the purposes of the present invention, “additive manufacturing process” refers to the selective polymerization of an article from a material and any post-production treatments that the article must undergo before a desired final product is produced. For the purposes of the present invention, “sustained tank polymerization,” “layer-by-layer technique,” ​​“stereolithography,” “inkjet head printing,” and other references specifically relating to the process of selectively polymerizing a material refer to the process of producing a solid article from a material as part of an additive manufacturing process. For the purposes of the present invention, “optical component” is defined as an article designed to be used in conjunction with an optical lens and / or an optical lens precursor, or preferably comprising one. For the purposes of the present invention, an article “precursor” is defined as a component intended to become an article after at least one further processing step. For the purposes of the present invention, "green body" or "optical green body" describes an optical lens, optical lens precursor, or optical component produced by selective polymerization, wherein the green body does not achieve complete polymerization of the resin throughout. Optical and ophthalmic lens parameters

[0046] In one aspect, the present invention provides additively manufactured optical lenses that meet the necessary optical and safety requirements for use in eyeglasses. An optical lens, as defined herein, refers to an optically transparent article through which light can be transmitted. Typically, an optical lens utilizes several variables to control how light is transmitted through the lens in order to produce predictable and reproducible optical results. The most important variables to consider when manufacturing an optical lens are the geometric shape of the lens and the material and optical properties of the material from which the lens is made. Examples of geometric variables include the diameter, shape, center point (mechanical axis) of each face of the lens, and, where applicable, the direction and radius of the curved surface. Examples of material and optical properties include refractive index, mechanical strength, chromatic dispersion, spherical power, density, UV absorption, optical clarity, and homogeneity. In an optical lens, there is an optical axis, which may differ from the mechanical axis. The mechanical axis of a lens is the geometric center of the lens. The optical axis is the axis that passes through the center of curvature of the lens. By controlling these different variables, a predictable pattern of light transmission through the lens can be determined.

[0047] Ophthalmic or corrective lenses, as defined herein, refer to optical lenses specifically designed to compensate for a person's unique visual disorder based on optical data. Ophthalmic lenses can predictably correct a person's unique visual disorder by utilizing the variables of the optical lens and the predictable optical patterns they generate in specific applications.

[0048] Lenses can take on various shapes, and different shapes offer different corrective capabilities. One category of shapes is the spherical lens, which is a lens that has a constant curvature across all meridians (any vertical axis). The three common spherical shapes that optical lenses can take are flat, concave, or convex. Flat lenses can offer very little corrective ability, and they are typically offered as a type of eyeglasses that do not provide vision correction, instead offering other benefits such as uncorrected sunglasses, uncorrected protective eyewear, or uncorrected athletic eyewear. A convex lens is a lens that has at least one outward-curving surface, i.e., a surface that is thicker along the mechanical and optical axes of the lens and thinner at the edge. Convex lenses focus light as it passes through them, and their use in optometry is to correct hyperopia. Convex lenses make the image appear closer due to the focusing of light as it passes through them. A concave lens is a lens that possesses at least one inwardly curved surface, i.e., a surface that is thicker at the edge and thinner along the mechanical and optical axes. A concave lens causes light to diverge outward as it passes through the lens, and due to this divergence of light as it passes through the lens, the image is perceived as being further away. Concave lenses are used in optometry to correct myopia. With respect to a given lens material, the greater the degree of curvature, the greater the corrective strength of the lens. The lens strength is measured by the focal length of the lens. With respect to a convex lens, the focal length is positive and is the point where light passing through the lens converges. With respect to a concave lens, the focal length is negative and is the point where light diverging outward from the lens will converge on the opposite side. Lens strength, also known as spherical power, is measured using diopters, which are a unit of refractive power and are equal to the reciprocal of the focal length in meters. In some embodiments, the present invention provides an optical lens having at least one spherical surface. In one embodiment, the present invention provides an optical lens having a concave surface. In another embodiment, the present invention provides an optical lens having a convex surface.

[0049] In addition to spherically curved lenses, cylindrically curved lenses are also used in optical lenses. In corrective lenses, cylindrically curved lenses are primarily used to correct astigmatism, i.e., irregularly shaped corneas that produce multiple focal points in a person's eye. Cylindrically curved lenses focus or defocus light in a single direction or line because they are curved in only one direction. On the other hand, spherically curved lenses focus light onto a single point. Corrective cylindrical lenses will have different curvatures and different meridians along the lens. Like spherical power, cylindrical power is also measured in diopters on the same scale. Furthermore, corrective cylindrical lenses used for astigmatism have an axis, which explains the position of the cylinder within the lens, corresponding to the irregular shape of the cornea. Cylindrical lenses focus or diverge the image in a direction perpendicular to the main axis, but do not alter the image parallel to the main axis. Unlike spherical lenses, axial-based correction focuses or diverges light in all directions, either to a single point or away from it. The lens power is determined by the following formula:

number

[0050] Lens shape, among other variables, is used in combination with each other to produce a corrective lens customized to each user's vision. For example, an optical lens may consist of a convex surface on one face of the lens having an intensity of +3.00 diopters and a concave surface on the other face having an intensity of -4.00 diopters, resulting in a lens with an overall intensity of -1.00 diopters, i.e., the sum of the intensities of the two surfaces within the lens. A suitable manufacturing process should preferably be capable of producing lenses with a wide range of potential shapes and curvatures. 3D printing is perfectly suited to this customization. Any form of 3D printing utilizes CAD design, which determines the pattern of material polymerization to be formed in the additively manufactured article. This makes 3D printing a highly capable system for producing personally customized lenses based on user-generated optical data, which can take into account any geometric shape. In one aspect, the present invention provides an additively manufactured optical lens having at least two curvatures, where at least two curvatures have independent spherical powers. In one aspect, the present invention provides additively manufactured optical lenses having total spherical powers of -50.00 to +50.00 diopters, -40.00 to +40.00 diopters, -30.00 to +30.00 diopters, -20.00 to +20.00 diopters, -10.00 to +10.00 diopters, -8.00 to +8.00 diopters, -7.00 to +7.00 diopters, -6.00 to +6.00 diopters, -5.00 to +5.00 diopters, -4.00 to +4.00 diopters, -3.00 to +3.00 diopters, -2.00 to +2.00 diopters, -1.00 to +1.00 diopters, or -0.50 to +0.50 diopters. In one aspect, the present invention provides additively manufactured optical lenses having total cylindrical powers of -6.00 to +6.00 diopters, -5.00 to +5.00 diopters, -4.00 to +4.00 diopters, -3.00 to +3.00 diopters, -2.00 to +2.00 diopters, -1.00 to +1.00 diopters, or -0.50 to +0.50 diopters.

[0051] A key element of any optical lens material is that the material is light-transmitting. This light transmittance is measured using the haze percentage, which is defined as the percentage of light that is diffused by more than 2.5° when passing perpendicularly through the material. When light is diffused by this angle or greater, the lens's ability to predictably alter the focus of an image is reduced. Perfectly optically transparent materials such as glass have a haze percentage of 0.0%. Plastic materials such as polycarbonate, which are typically used in the manufacture of optical lenses, have a haze percentage of 1.0%. In some respects, the present invention provides additively manufactured optical lenses having a haze percentage of less than 6.0%, more preferably less than 5.0%, more preferably less than 4.0%, more preferably less than 3.0%, or even more preferably less than 2.0% after printing, but before polishing. In another aspect, the present invention provides additively manufactured optical lenses having a haze percentage of 4.0% to 6.0%, more preferably 3.0% to 6.0%, after printing, but before polishing. In another aspect, the present invention provides additively manufactured optical lenses having a haze percentage of 3.0% to 5.0%, more preferably 2.0% to 4.0%, more preferably 1.0% to 4.0%, or more preferably 1.0% to 3.0%.

[0052] In one aspect, the present invention provides additively manufactured and finished optical lenses having a haze percentage of less than 22.0%, more preferably less than 11.0%, more preferably less than 0.50%, more preferably less than 0.22%, and even more preferably less than 0.1% after polishing and coating. In another aspect, the present invention provides additively manufactured and finished optical lenses having a haze percentage of 0.5% to 3.0%, more preferably 0.5% to 1.0% after polishing and coating. In yet another aspect, the present invention provides additively manufactured and finished optical lenses having a haze percentage of 0.05% to 2.0%, more preferably 0.05% to 1.0%, more preferably 0.05% to 0.5%, or more preferably 0.3% to 0.5% after polishing and coating. Haze measurement can be performed according to ASTM D1003. The above haze values ​​are preferably transmitted haze.

[0053] The components of an optical lens are light-transmitting materials from which the lens is constructed. One requirement for any suitable optical lens material is its refractive index. The refractive index of a material defines the speed at which light travels through the material compared to light traveling in a vacuum, and is determined by the change in the angle of light as it passes from one material to another. The refractive index is determined by the optical density of the material, i.e., its absorbance, which indicates the intensity of light entering the material compared to the intensity of light leaving the material. Snell's law, which is described below, can be used to determine the refractive index of a medium.

number

[0054] In some respects, embodiments of the present disclosure provide additively manufactured optical lenses having a refractive index of 1.4 to 1.8, more preferably 1.45 to 1.8, more preferably 1.5 to 1.8, more preferably 1.53 to 1.8, and even more preferably 1.55 to 1.8. In some respects, the present invention provides additively manufactured optical lenses having a refractive index of 1.4 to 1.74, more preferably 1.45 to 1.74, more preferably 1.5 to 1.74, more preferably 1.53 to 1.74, more preferably 1.55 to 1.74, or even more preferably 1.60 to 1.74. In another aspect, the present invention provides additively manufactured optical lenses having a refractive index of 1.4 to 1.70, more preferably 1.45 to 1.70, more preferably 1.5 to 1.70, more preferably 1.53 to 1.70, more preferably 1.55 to 1.70, or even more preferably 1.60 to 1.70. In another aspect, the present invention provides additively manufactured optical lenses having a refractive index of 1.4 to 1.65, more preferably 1.45 to 1.65, more preferably 1.5 to 1.65, more preferably 1.53 to 1.6, or even more preferably 1.55 to 1.65.

[0055] In another aspect, embodiments of the present disclosure provide additively manufactured infrared lenses having a refractive index of at least 1.70, more preferably at least 1.80, more preferably at least 1.90, more preferably at least 2.00, and even more preferably above 1.60. In another aspect, the present invention provides additively manufactured infrared lenses having a refractive index of 1.7 to 2.3, more preferably 1.7 to 2.2, or more preferably 1.7 to 2.1.

[0056] When manufacturing lenses, the refractive index is selected based on the product the manufacturer aims to produce. A refractive index of 1.50–1.53 is often selected for children's lenses. 1.55–1.60 is used for adults, often with single-vision lenses. For the elderly, who require high levels of correction and desire lighter lenses, a refractive index of 1.58–1.74 is ideal for progressive lenses. For lenses requiring infrared transmission or for use with waveguides, a range of 1.70–2.9 is required. Within that range, the ideal range of 1.70–2.10 is desirable for materials without nanoparticle or microparticle fillers.

[0057] Another requirement for any suitable optical lens material is its chromatic aberration or dispersion. Chromatic aberration is defined as the difference in refraction between waves of light having different wavelengths. As a result of chromatic aberration, a single material will have different refractive indices with respect to light of different wavelengths. Chromatic aberration is measured using the Abbe number, i.e., the V number, which is calculated based on the refractive indices with respect to three standardized wavelengths of light, namely, yellow from sodium (598.2 nm), red from hydrogen (656.3 nm), and blue from hydrogen (486.1 nm). The Abbe number is calculated using the following formula:

number

[0058] Both the refractive index and the Abbe number are used to determine the amount by which the focal point of an image changes as it passes through a lens. A raw material having a suitable optical lens material is selected, provided both the refractive index and the Abbe number are known, in order to achieve a certain spherical power. Using this knowledge, the lens is shaped to achieve a specific geometric shape that will give the desired spherical power.

[0059] In addition to the optical properties of a lens, its mechanical properties must also be considered. The primary mechanical concern concerns user safety. An optical lens must not, under reasonable conditions, break, shatter, or otherwise injure the user's eye. Furthermore, the lens must not deform to prevent changes in spherical power and potential visual problems for the user. A standard ball drop test is used to test the mechanical strength of an optical lens and determine whether it meets the criteria for mechanical fracture or deformation. According to ISO 14889:1997, an uncut, finished lens must be able to withstand a steel ball with a diameter of 22 mm, which is dropped into the lens with a force of approximately 100 N applied to the lens at approximately 23°C for approximately 10 seconds. A lens will be considered fractured if the test causes cracks in the lens through two or more pieces throughout the entire thickness of the lens, or if at least 5 mg of lens material peels off from the surface. To test for deformation, a piece of carbon paper is placed directly beneath the lens during the O14889:1997 ball drop test, and the lens is considered deformed if a mark appears on the paper. In one aspect, the present invention provides additively manufactured lenses that meet the ISO standard for uncut finished lenses with respect to mechanical strength.

[0060] Another parameter to consider when determining a suitable optical lens material is the density of the material. Typical glass materials used for optical lenses have a density of 2.5 g / cm³. 3 ~4.3g / cm 3 It has a density of 1.11 g / cm³. Typical glass materials used for optical lenses have a density of 1.11 g / cm³. 3(Trivex™) ~1.46 g / cm³ 3 It has a density of MR-174). In one aspect, the present invention is 1.5 g / cm³. 3 Less than, more preferably 1.3 g / cm³ 3 Less than, more preferably 1.2 g / cm³ 3 Less than, more preferably 1.1 g / cm³ 3 Less than, more preferably 1.0 g / cm³ 3 The present invention provides additively manufactured optical lenses having a density of less than 0.9 g / cm³. In one aspect, the present invention provides additively manufactured optical lenses having a density of less than 0.9 g / cm³. 3 ~1.5g / cm 3 More preferably, 0.9 g / cm³ 3 ~1.3g / cm 3 More preferably, 0.9 g / cm³ 3 ~1.2g / cm 3 , or more preferably 0.9 g / cm³ 3 ~1.1g / cm 3 The present invention provides additively manufactured optical lenses having a density of 1.1 g / cm³. In one aspect, the present invention provides additively manufactured optical lenses having a density of 1.1 g / cm³. 3 ~1.5g / cm 3 More preferably, 1.0 g / cm³ 3 ~1.3g / cm 3 , or more preferably 1.1 g / cm³ 3 ~1.3g / cm 3 The present invention provides additively manufactured optical lenses having a density of [density].

[0061] In one aspect, the present invention provides an optical lens additively manufactured from a given resin having a density lower than that of an optical lens made from a given resin using standard techniques for cast optical lenses. A sustained vat polymerization printing process can additively manufacture a lens using a given thermosetting resin having a lower density than that of a lens manufactured using that resin through casting or pressure molding techniques. This is a result of sustained resin flow during the sustained vat polymerization printing process, which can result in less overall crosslinking within the polymer network compared to conventional casting techniques. In one aspect, the present invention provides an optical lens comprising a polymerized thermosetting resin, the optical lens having a density lower than that of an optical lens comprising the same polymerized thermosetting resin manufactured using a casting process. In one aspect, this density difference is at least 0.05 g / cm³ 3 More preferably, at least 0.1 g / cm³ 3 Preferably, at least 0.2 g / cm³ 3 , more preferably, at least 0.3 g / cm³ 3 , or more preferably, at least 0.5 g / cm³ 3 In another respect, the density of the optical lens of the present invention is 0.05 g / cm³ higher than that of an optical lens comprising the same polymerized thermosetting resin manufactured using a casting process. 3 ~0.5g / cm 3 Low, preferably 0.05 g / cm³ 3 ~0.4g / cm 3 Low, 0.10 g / cm³ 3 ~0.5g / cm 3 Low, 0.10 g / cm³ 3 ~0.4g / cm 3 Low, 0.20 g / cm³ 3 ~0.5g / cm 3 Low, 0.02 g / cm³ 3 ~0.4g / cm 3 Low, 0.30 g / cm³ 3 ~0.4g / cm 3 Lower, or 0.30 g / cm³ 3 ~0.5g / cm 3 It can have a low density.

[0062] Specifically, this is used to impart attractive directivity to the network and to specifically integrate the most optically active components into the polymer backbone rather than having the most compressed network possible. It is also used for polarizing, photochromic, or liquid crystalline molecules that require directivity to have their desired properties within the lens. With respect to lenses that do not possess these properties, it is sometimes preferable to have a smaller density difference, or no density difference at all, compared to optical lenses manufactured using standard techniques for cast optical lenses. In one aspect, the density of the optical lens of the present invention, compared to the density of an optical lens comprising the same polymerized thermosetting resin manufactured using a casting process, is 0.4 g / cm³. 3 Or less, more preferably 0.3 g / cm³ 3 Or less, more preferably 0.2 g / cm³ 3 Or less, more preferably 0.1 g / cm³ 3 Or less, more preferably 0.05 g / cm³ 3 or less. Suitable material properties for sustained tank polymerization of optical lenses

[0063] To manufacture optical lenses that meet or exceed industry standards using a sustained tank polymerization process, the resin formulation must satisfy certain requirements. Firstly, the resin formulation must be optically transparent unless the desired lens is a sunglass lens or another lens where partial absorbance is desired; in that case, the resin formulation should preferably be translucent. Secondly, the resin formulation must meet the refractive index and Abbe number thresholds after the lens additive manufacturing process is complete.

[0064] Sustained tank polymerization methods have additional criteria that the resin formulation should meet, and there are many components that can be added to the resin formulation that may significantly affect the properties of the final product. In some embodiments, a suitable resin formulation is a thermosetting resin formulation. In some embodiments, a suitable resin formulation comprises one or more monomers, one or more oligomers, or equivalents, or any combination thereof, and an enhancer. Suitable monomers and / or oligomers are polar or nonpolar, organic or inorganic, saturated or unsaturated, monofunctional or polyfunctional, or equivalents, or any combination thereof. Suitable monomers and / or oligomers include, but are not limited to, acrylates, methacrylates, vinyls, and equivalents. In some embodiments, a suitable resin formulation for optical lens manufacturing would be optically transparent. In some embodiments, a suitable resin formulation for optical lens manufacturing would be optically translucent. In some embodiments, a suitable resin formulation further comprises a thermal initiator. In some embodiments, a suitable resin formulation further comprises a UV inhibitor.

[0065] The optical properties of a resin formulation depend on its specific components. Non-limiting examples of monomers that affect the optical properties of a resin formulation include aromatic monomers and sulfur-containing monomers. In some embodiments, a suitable resin formulation further comprises at least one aromatic ring component. Aromatic rings can be classified by the number of functional groups bonded to the ring. In some embodiments, the at least one aromatic ring component further comprises a monofunctional aromatic ring, a difunctional aromatic ring, a trifunctional aromatic ring, a tetrafunctional aromatic ring, or a combination thereof. In some embodiments, a suitable resin formulation further comprises a sulfur monomer and / or oligomer. In some embodiments, during polymerization, the sulfur monomer and / or oligomer are present in the polymer backbone of the resin formulation. In some embodiments, during polymerization, the thiol monomer is a pendant group. Applications of sustained tank polymerization of optical lenses

[0066] In one aspect, the present invention provides optical components having a homogeneous polymer network. In another aspect, the present invention provides optical lenses having a homogeneous polymer network. For the purposes of the present invention, a polymer network is a “homogeneous polymer network” if it lacks distinctly different and perceptible imperfections such as layer lines. Conventional additive manufacturing techniques such as stereolithography, selective laser sintering, and inkjet head printing utilize layer-by-layer techniques. Layer-by-layer stereolithography involves curing an entire layer of resin, then moving the cured layer away from the energy source, allowing new resin to flow in and another layer to be cured. Layer-by-layer techniques have weak interlayer adhesion, resulting in imperfections present between layers, often referred to as “layer lines” or “boundaries.” These layer lines interfere with the formation of a truly homogeneous polymer network because the polymer network at the interlayer boundaries differs from the polymer network of the layer itself, which can weaken the strength of the product in the z-direction, i.e., the direction in which the object is printed. From the perspective of optical lens manufacturing, layer lines can affect the optical properties of a lens, generating visual and optical imperfections that impair the visual clarity of the lens. While layer-by-layer techniques allow for the production of layers so thin that they are imperceptible to the eye, inconsistencies in layer lines still exist within the polymer network. The more layer lines present in a lens, the more they will diffuse light as it passes through the lens. Therefore, lenses produced by layer-by-layer techniques typically do not meet the haze % threshold for use in eyeglasses. Techniques utilizing smaller layers can allow for higher precision during the printing process, but they increase the diffusivity of layer lines, reducing the intensity of the final product and slowing down the printing process. As the depth of the layers increases, the required precision of the printing process decreases, and the difference between the top and bottom polymerization of the layers increases. Method for manufacturing lenses via sustained tank polymerization

[0067] Establishing a pre-gelling zone thickness ("PGZT") can be important for printing suitable optical lenses. The pre-gelling zone is the region where covalent bonding occurs between resin monomers and / or oligomers through radiation-induced reactions, preferably photochemical reactions. The average static viscosity within the pre-gelling zone is increased compared to the bulk resin. PGZT is the distance in the z-direction between the point where curing begins (i.e., the covalent bonding between resin monomers and / or oligomers) and the gel point boundary ("GP"). A gel is a state in which the resin has a sufficiently formed network to maintain its shape, but still contains a portion of liquid resin within the gel body. The gel point boundary is where the body first reaches gelation, as shown by the boundary GP in Figure 1. Above the boundary GP, the body is either gel and / or solid. Below the boundary GP, the body is liquid, with increased viscosity compared to the bulk resin.

[0068] The resin voxels will gel when they achieve a sufficient amount of radiation. The pre-gelled zone thickness is resin-dependent and inversely proportional to the reactivity with respect to a given light intensity. The reactivity may depend on all the components constituting the resin, including initiators and inhibitors. The intensity at depth z for a resin with a molar extinction coefficient ∈ is: [ka] It is. Watts / cm² 3The intensity, measured in units of , determines the amount of energy absorbed by the resin voxels. The pre-gelling zone thickness may be increased, for example, by reducing the photoinitiator concentration (unless the photoinitiator concentration is such that it acts as both an initiator and an inhibitor), or by reducing the light intensity so that polymerization occurs at a slower rate. If polymerization occurs at a slower rate in a sustained vat polymerization process while the tensile rate remains constant, the gel point will be higher because a given voxel takes longer to absorb the required amount of radiation and begin gelling. Changing the tensile rate for printing will change the pre-gelling zone thickness in the same direction. Changing the radiation intensity will change the pre-gelling zone thickness inversely.

[0069] The pre-gelation zone can be measured in several different ways. Optically, the interface can be seen by a camera from the side where printing is occurring. It can also be measured through X-ray tomography. Furthermore, it can be correlated through the force between the part and the interface.

[0070] Final curing on the printer is separate from the pre-gelling zone depth. The only constraint is that the final curing on the printer must be higher than the curing percentage required to reach the gel point. The exact percentage depends on the oligomers and monomers in the resin. In some embodiments, the final curing percentage on the printer is 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 99%, or 100%, depending on the desired final product and any post-processing requirements.

[0071] The pre-gelling zone thickness is typically not uniform across the entire cross-section in the x and y directions of the printed part. This can occur because the resin progresses from outside the part curing area, where the bulk resin flows within and through the radiating area, entering the first edge of the printed part and reaching both the center and the second distal edge of the part. Using uniform radiation across the cross-section, it would be expected that the center of the pre-gelling zone may have a thinner thickness than the edge of the part. This is because the pre-gelling zone thickness derives from the cumulative irradiation dose of the resin voxels that allows curing into the solid body. This difference may be more pronounced at the first edge. This gel point boundary can be flattened or adjusted by varying the intensity of the radiating flow velocity from the center to the edge of the part. The intensity can also be varied to make the edge higher than the center, which would reduce the forces on the interface and prevent interface disturbance or damage. When the resin or interface is moving, as in the case of WHARP, the pre-gelling zone thickness will have directionality with respect to it. This is often linked to the cumulative irradiation dose, which is integrated over the flow path length. In the case of HARP with uniform intensity, as the resin and oil flows from left to right, the pre-gelling zone thickness is thicker on the left side of the part and thinner on the right side of the part.

[0072] Several different methods exist for measuring PGZT, which can be specified with respect to a particular measurement. Referring to the xy cross-section of the print, the pre-gelling zone thickness can be measured at different locations, e.g., the first edge, second edge, center of the printed part, a location identified as having the maximum pre-gelling zone thickness in the xy cross-section, and / or a location identified as having the minimum pre-gelling zone thickness in the xy cross-section. To locate the center of the cured part in the xy dimensions, pixels in the xy direction can be located at the center of the radial print width, and the pre-gelling zone thickness can be measured at the corresponding point in the Z direction. Alternatively, the pre-gelling zone thickness can be measured within a region in the xy cross-section. When viewing the cross-section, the pre-gelling zone thickness can be measured as the average of the pre-gelling zone thicknesses at two opposing locations 1 mm, 2 mm, or 3 mm from each center point, respectively.

[0073] The pre-gelled zone thickness can also be measured by determining the average thickness at all locations along the width of the body, excluding a 1 mm width above each outer edge of the body, or by determining the average thickness at all locations along the width of the body, excluding a 2 mm width above each outer edge of the body. The pre-gelled zone thickness can also be measured by determining the average thickness at all locations along the width of the body, excluding a portion within 1 mm of the center of the body, or by determining the average thickness at all locations along the width of the body, excluding a portion within 2 mm of the center of the body.

[0074] Embodiments of the present invention have the advantage of utilizing a thicker pre-gelling zone thickness. In some embodiments, the pre-gelling zone thickness, measured at the first edge, may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1,000 microns, up to 1,500 microns, up to 2,000 microns, up to 2,500 microns, up to 3,000 microns, up to 4,000 microns, or up to 5,000 microns. In one aspect, the present invention provides an additively manufactured optical lens using a pre-gelling zone thickness of 100 to 5,000 microns, preferably 100 to 4,000 microns, preferably 100 to 3,000 microns, preferably 100 to 2,000 microns, more preferably 100 to 1,000 microns, more preferably 200 to 800 microns, more preferably 200 to 600 microns, or more preferably 150 to 400 microns at the first edge. In another aspect, the present invention provides an additively manufactured optical lens using a pre-gelling zone thickness of 200 to 3,000 microns, preferably 200 to 2,000 microns, preferably 200 to 1,000 microns, more preferably 200 to 500 microns, more preferably 200 to 400 microns, or more preferably 200 to 300 microns at the first edge. In one aspect, the present invention provides an additively manufactured optical lens using a pre-gelling zone thickness of 300 to 3,000 microns, preferably 300 to 2,000 microns, preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns at the first edge.

[0075] In some embodiments, the pre-gelling zone thickness, measured as the average of the pre-gelling zone thicknesses of the first and second edges, may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least about 300 microns, at least up to 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1,000 microns, up to 1,500 microns, up to 2,000 microns, up to 2,500 microns, up to 3,000 microns, up to 4,000 microns, or up to 5,000 microns. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 100 to 3,000 microns, more preferably 100 to 2,000 microns, more preferably 100 to 1,000 microns, more preferably 100 to 500 microns, more preferably 100 to 400 microns, or more preferably 100 to 300 microns, as measured as the average of the pre-gelling zone thicknesses of the first and second edges. In another aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 200 to 3,000 microns, more preferably 200 to 2,000 microns, more preferably 200 to 1,000 microns, more preferably 200 to 500 microns, more preferably 200 to 400 microns, or more preferably 200 to 300 microns, as measured as the average of the pre-gelling zone thicknesses of the first and second edges. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns, which is measured as the average of the pre-gelling zone thicknesses of the first and second edges.

[0076] In some embodiments, the pre-gelled zone thickness, measured at the center, may be at least 50 microns, more preferably at least 100 microns, more preferably at least 200 microns, more preferably at least about 300 microns, preferably at least up to 400 microns, more preferably at least 500 microns, more preferably at least 600 microns, more preferably at least 800 microns, and up to 1,000 microns, up to 1,500 microns, up to 2,000 microns, up to 2,500 microns, up to 3,000 microns, up to 4,000 microns, or up to 5,000 microns. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelled zone thickness at the center of 100 to 3,000 microns, more preferably 100 to 2,000 microns, more preferably 100 to 1,000 microns, more preferably 100 to 500 microns, more preferably 100 to 400 microns, more preferably 100 to 300 microns. In one aspect, the present invention provides additively manufactured optical lenses using a central pre-gelling zone thickness of 200 to 3,000 microns, more preferably 200 to 2,000 microns, more preferably 200 to 1,000 microns, more preferably 200 to 500 microns, more preferably 200 to 400 microns, and more preferably 200 to 300 microns. In another aspect, the present invention provides additively manufactured optical lenses using a central pre-gelling zone thickness of 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, and even more preferably 250 to 350 microns.

[0077] In some embodiments, the pre-gelling zone thickness at a location identified as having the maximum pre-gelling zone thickness in the xy cross-section may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1,000 microns, up to 1,500 microns, up to 2,000 microns, up to 2,500 microns, up to 3,000 microns, up to 4,000 microns, or up to 5,000 microns. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 100 to 3,000 microns, more preferably 100 to 2,000 microns, more preferably 100 to 1,000 microns, more preferably 100 to 500 microns, more preferably 100 to 400 microns, or more preferably 100 to 300 microns at a location identified as having the maximum pre-gelling zone thickness in the xy cross-section. In one aspect, the present invention provides an additively manufactured optical lens using a pre-gelling zone thickness of 200 to 3,000 microns, more preferably 200 to 2,000 microns, more preferably 200 to 1,000 microns, more preferably 200 to 500 microns, more preferably 200 to 400 microns, or even more preferably 200 to 300 microns, at a location identified as having the maximum pre-gelling zone thickness in the xy cross-section. In another aspect, the present invention provides an additively manufactured optical lens using a pre-gelling zone thickness of 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns, at a location identified as having the maximum pre-gelling zone thickness in the xy cross-section.

[0078] In some embodiments, the pre-gelling zone thickness is measured as the average of the pre-gelling zone thickness at points located on opposite sides at a distance of 1 mm, 2 mm, or 3 mm from the center; or by determining the average thickness at all locations along the width of the body, excluding a width of 1 mm above each outer edge of the body; or by determining the average thickness at all locations along the width of the body, excluding a width of 2 mm above each outer edge of the body; or by determining the average thickness at all locations along the width of the body, excluding a portion within 1 mm of the center of the body; or by determining the average thickness at all locations along the width of the body, excluding a portion within 2 mm of the center of the body. In each of those cases, the PGZT may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1,000 microns, up to 1,500 microns, up to 2,000 microns, up to 2,500 microns, up to 3,000 microns, up to 4,000 microns, or up to 5,000 microns. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 100 to 3,000 microns, more preferably 100 to 2,000 microns, more preferably 100 to 1,000 microns, more preferably 100 to 500 microns, more preferably 100 to 400 microns, or more preferably 100 to 300 microns, as measured in this paragraph. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 200 to 3,000 microns, more preferably 200 to 2,000 microns, more preferably 200 to 1,000 microns, more preferably 200 to 500 microns, more preferably 200 to 400 microns, or more preferably 200 to 300 microns, as measured in this paragraph.In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns, as measured in this paragraph.

[0079] In some embodiments, the pre-gelling zone thickness at a location identified as having a minimum pre-gelling zone thickness in the xy cross-section may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1,000 microns, up to 1,500 microns, up to 2,000 microns, up to 2,500 microns, up to 3,000 microns, up to 4,000 microns, or up to 5,000 microns. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 100 to 3,000 microns, more preferably 100 to 2,000 microns, more preferably 100 to 1,000 microns, more preferably 100 to 500 microns, more preferably 100 to 400 microns, or more preferably 100 to 300 microns at a location identified as having a minimum pre-gelling zone thickness in the xy cross-section. In one aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 200 to 3,000 microns, more preferably 200 to 2,000 microns, more preferably 200 to 1,000 microns, more preferably 200 to 500 microns, more preferably 200 to 400 microns, or more preferably 200 to 300 microns, at a location identified as having a minimum pre-gelling zone thickness in the xy cross-section. In another aspect, the present invention provides additively manufactured optical lenses using a pre-gelling zone thickness of 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns, at a location identified as having a minimum pre-gelling zone thickness in the xy cross-section.

[0080] In other embodiments, the pre-gelling zone thickness at a location identified as having the minimum pre-gelling zone thickness in the xy cross-section may be, advantageously, less than 200 microns, more preferably less than 150 microns, more preferably less than 100 microns, or particularly more preferably less than 50 microns, including 0 microns.

[0081] With respect to embodiments having a thinner pre-gelling zone thickness at locations identified as having the minimum pre-gelling zone thickness in the xy cross-section as described above, the additively manufactured optical lens uses a pre-gelling zone thickness of 250 to 3,000 microns, more preferably 250 to 2,000 microns, more preferably 250 to 1,000 microns, more preferably 250 to 500 microns, more preferably 250 to 400 microns, more preferably 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns at the first edge.

[0082] With regard to other embodiments having a thinner pre-gelling zone thickness in the xy cross-section identified as having the minimum pre-gelling zone thickness as described above, the additively manufactured optical lens uses a pre-gelling zone thickness of 250 to 3,000 microns, more preferably 250 to 2,000 microns, more preferably 250 to 1,000 microns, more preferably 250 to 500 microns, more preferably 250 to 400 microns, more preferably 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns, measured as the average thickness at the first and second edges.

[0083] With regard to further embodiments having a thinner pre-gelling zone thickness in a location identified as having the minimum pre-gelling zone thickness in the xy cross-section as described above, the additively manufactured optical lens uses a pre-gelling zone thickness of 250 to 3,000 microns, more preferably 250 to 2,000 microns, more preferably 250 to 1,000 microns, more preferably 250 to 500 microns, more preferably 250 to 400 microns, more preferably 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns, measured as the average thickness at the first and second edges.

[0084] With regard to other embodiments having such thinner pre-gelled zone thicknesses as described above, the additively manufactured optical lens uses a pre-gelled zone thickness of 250 to 3,000 microns, more preferably 250 to 2,000 microns, more preferably 250 to 1,000 microns, more preferably 250 to 500 microns, more preferably 250 to 400 microns, more preferably 300 to 3,000 microns, more preferably 300 to 2,000 microns, more preferably 300 to 1,000 microns, more preferably 300 to 500 microns, more preferably 300 to 400 microns, or even more preferably 250 to 350 microns at locations identified as having a minimum pre-gelled zone thickness in the xy cross-section.

[0085] The pre-gelled zone thickness may be applicable only to the internal region of the part and once a steady state can be reached. If there are start and stop cycles in the printing, then this cannot be applied. This can be defined as a complete set of slices of the part, or considered on a per-voxel basis, focusing on each individually. Thus, with respect to the method of using any of the pre-gelled zone thicknesses described above, the start and end portions of the printing process will typically not utilize such pre-gelled zone thicknesses throughout, but will typically have transition thicknesses. At the start of the process, the thickness grows to the pre-gelled zone thickness described above. At the end of the process, the thickness decreases from the pre-gelled zone thickness described above. With respect to aspects of the invention as herein, the printing process utilizes the thicker thicknesses described in the above paragraphs over at least 50.0%, preferably 60.0%, more preferably 70.0%, more preferably 80.0%, more preferably 90.0%, or more preferably 95.0% of the printing time for the lens. With regard to aspects of the present invention as described herein, the printing process utilizes the thicker thickness described in the above paragraphs over 60.0% to 99% of the printing time for the lens, 70.0% to 99% of the printing time for the lens, 80.0% to 99% of the printing time for the lens, 90.0% to 99% of the printing time for the lens, or 95.0% to 99% of the printing time for the lens. With regard to aspects of the present invention as described herein, the printing process utilizes the thicker thickness described in the above paragraphs over 60.0% to 95% of the printing time for the lens, 70.0% to 95% of the printing time for the lens, 80.0% to 95% of the printing time for the lens, or 90.0% to 95% of the printing time for the lens.

[0086] With respect to aspects of the present invention as described herein, the printing process utilizes a greater thickness, as described in the preceding paragraph, across the internal region of the body B, extending at least one pre-gelling zone thickness from the edge of the lens, preferably at least two pre-gelling zone thicknesses from the edge of the lens, more preferably at least three pre-gelling zone thicknesses from the edge of the lens, more preferably at least four pre-gelling zone thicknesses from the edge of the lens, or at least five pre-gelling zone thicknesses from the edge of the lens.

[0087] When multiple parts exist during printing, they can be treated as separate parts using separate pre-gelling zones. Therefore, when printing lenses and frames simultaneously, only the portion containing the optical components of the lens needs to have a sufficiently large pre-gelling zone, while the frame portion or any non-optically active portion of the final part can have a smaller (or larger) pre-gelling zone than that found for the optical components. Alternatively, they can have identical zones to simplify calculations for the user. Similarly, the settings for support can also differ. They can even be printed layer by layer, and then the printing continues to transition once it reaches the optically relevant portion of the lens.

[0088] Sustained tank polymerization provides a method for additive manufacturing articles without the layer lines resulting from layer-by-layer printing. By continuously moving the article being manufactured while polymerizing, the sustained tank polymerization technique can produce articles with a truly homogeneous polymer network with the required level of precision. From the viewpoint of optical lens manufacturing, sustained tank polymerization provides a method for additive manufacturing optical lenses that lack the visual and optical imperfections present in optical lenses resulting from conventional layer-by-layer techniques. Layer-by-layer printing utilizes a pre-gelling zone depth of 0. This allows the gel to grow from the interface until it reaches a fully solidified body at a height of one layer above the interface. This is fundamentally different from the embodiments described herein, as the resin does not move while curing. This creates differences at the top and bottom of each layer in terms of final curing, with respect to the printer percentage.

[0089] A key aspect of the systems described herein is that the final curing on the printer is sufficiently uniform within the area utilizing the printing process and extends beyond the pre-gelling zone before hardening. With respect to aspects of the present invention as described herein, the variation in final curing on the printer within the area of ​​interest, as described above, is less than 40%, preferably less than 30%, more preferably less than 20%, more preferably less than 15%, preferably less than 10%, more preferably less than 5%, more preferably less than 3%, and even more preferably less than 1%.

[0090] The homogeneity of an optical lens can be measured using optical metric. In some embodiments, a wavefront sensor is used to perform measurements for optical metric. In some embodiments, a Shack-Hartmann wavefront sensor is used. Utilizing this sensor involves shining light through the lens onto various lenslets. These lenslets measure the degree to which the light striking them is tilted. When these tilt measurements are combined, the overall degree of wavefront tilt can be measured. An optimally homogeneous network will have only very slight tilt due to the minimal presence of optical aberrations.

[0091] In one aspect, the present invention provides an optical lens having a homogeneous polymer network with a directional component. In another aspect, the present invention provides an optical component precursor having a homogeneous polymer network with a directional component. For the purposes of the present invention, the directional component is defined as the overall arrangement order of the polymerization of components of the resin formulation in the pulling direction during the additive manufacturing process. The presence of monofunctional, difunctional, trifunctional, and tetrafunctional aromatic rings in the resin formulation contributes to this overall arrangement order. Difunctional and trifunctional aromatic rings are aligned in the pulling direction and provide the directional component, while monofunctional and tetrafunctional rings are not aligned in the pulling direction and provide disorder in all directions. This combination provides an overall arrangement order of polymerization in the pulling direction, while also maintaining a homogeneous network throughout the manufactured article. Furthermore, the overall amount of directionality can be influenced by the ratio of difunctional and trifunctional rings, depending on the ratio of monofunctional and tetrafunctional rings. In some embodiments, increasing the amount of monofunctional rings relative to other rings in the resin formulation reduces the directionality of the final optical lens.

[0092] This directivity is unavailable with conventional layer-by-layer techniques. Furthermore, any directivity obtained from layer-by-layer stereolithography would be perpendicular to the direction of movement due to this weak interlayer bonding, resulting in a non-homogeneous network. This technique is also unavailable for thermosetting lens raw materials manufactured using conventional casting techniques, as those techniques involve a holding period during polymerization, during which the resin remains steady, allowing it to achieve maximum disorder. Directional sides are a result of the movement of the polymerizing resin as it hardens. Conventional casting and conventional layer-by-layer additive manufacturing techniques all involve raw products that remain steady while the resin hardens, thus limiting their ability to impart directional sides to the polymer network of the manufactured article. In some respects, this directivity can be perceived as different directional properties when the lens is printed in different directions. For example, the additively manufactured lens of the present invention may have directional components with different refractive indices when light is shone through different directions perpendicular to the lens. In some embodiments, this difference is referred to as the Δ refractive index, where it is at least 0.01, more preferably at least 0.02, more preferably at least 0.03, more preferably at least 0.04, and more preferably at least 0.05. The Δ refractive index of the lens can be as much as 0.10 or even further 0.15. In some embodiments, light illuminating through the lens is refracted to a different degree than light illuminating through the lens perpendicular to the printing direction. Thus, the lenses provided by the present invention can have a refractive index in one direction that is different from the refractive index perpendicular to that direction. For example, if additively manufactured to have a directional component, it will have different tensile strengths in different directions.

[0093] The difference between the lenses provided by the present invention and those produced using conventional techniques may be evident in the differences in mechanical properties imparted to the homogeneous network by the directional side. In one aspect, the present invention provides an optical lens having a tensile strength at the directional side of the homogeneous polymer network of the lens that is at least 3.0% stronger, more preferably at least 5.0% stronger, more preferably at least 10% stronger, more preferably at least 15.0% stronger, more preferably at least 20.0% stronger, and more preferably at least 25.0% stronger, compared to the direction perpendicular to the directional side of the homogeneous network. In one aspect, the present invention provides an optical lens having, in the direction perpendicular to the directional side of the homogeneous polymer network of the lens, at least 3.0% greater extension, more preferably at least 5.0% greater extension, more preferably at least 10.0% greater extension, more preferably at least 15.0% greater extension, more preferably at least 20.0% greater extension, more preferably at least 25.0% greater extension, and up to 50.0% greater extension, compared to the direction perpendicular to the directional side of the homogeneous network.

[0094] In addition to the unique mechanical properties of an optical lens having a homogeneous polymer network with directional sides, there are also unique optical properties. In one aspect, the present invention provides an optical lens having a homogeneous polymer network with directional sides, which has a Δrefractive index of at least 0.01, more preferably at least 0.02, more preferably at least 0.03, more preferably at least 0.04, more preferably at least 0.05, and up to 0.10, when light is illuminating the lens in the same direction as the directional sides compared to when light is illuminating the lens perpendicular to the directional sides.

[0095] In one respect, the intensity of the directional side, and therefore the difference in the mechanical and optical properties of the lens in the directional side compared to the direction perpendicular to the directional side, can be considered as the total amount of aromatic rings aligned in a certain direction. This means that an optical lens constructed from a resin formulation having a higher total amount of monofunctional and trifunctional aromatic rings will have a stronger directional side and, therefore, a greater difference in mechanical and optical properties in the direction of the directional side compared to the direction perpendicular to the directional side, than an optical lens constructed from a resin formulation having a lower total number of difunctional and trifunctional aromatic rings. In addition, an optical lens constructed from a resin formulation having a given amount of aromatic rings will have a stronger directional aspect than an optical lens constructed from a resin formulation having the same amount of total aromatic rings, but with a lower percentage of difunctional and trifunctional aromatic rings compared to monofunctional and tetrafunctional aromatic rings, if that given amount of aromatic rings has a higher percentage of difunctional and trifunctional aromatic rings compared to monofunctional and tetrafunctional aromatic rings. Optical lenses having a homogeneous polymer network with a directional aspect that affects the mechanical and optical properties of the lens are not available in conventional optical lens manufacturing or conventional additive manufacturing techniques. Through experiments with resin formulations, it can be determined that an appropriate number of aromatic rings and the ratio of difunctional / trifunctional rings to monofunctional / tetrafunctional rings imparts a sufficiently strong directional aspect without sacrificing the mechanical and optical properties of the lens perpendicular to the directional aspect.

[0096] Despite the potential advantages of directivity within lenses, excessive directivity can lead to optical or mechanical imperfections within the optical components, which will ultimately affect performance. Within a product with a homogeneous network, there is a degree of homogeneity, and higher homogeneity is achieved through a more relaxed network. A relaxed network also improves the consistency of optical properties throughout the lens. Comparing two polymer networks, a network is more relaxed when the chains of the polymer network are not aligned in the same direction. This is due to the chains achieving a lower energy state because aligned chains exert stress on each other. On the other hand, a relaxed network allows the chains to move in all directions, which can relieve the stress that aligned chains exert on each other. When polymers are formed under force, a polymer network formed more slowly achieves a more relaxed network than a polymer formed rapidly. In sustained tank polymerization, a more relaxed network can be achieved by reducing the rate of attraction in conjunction with reducing the reactivity of the resin. Sustained pulling exerts an adhesive force on the green body as the resin is pulled outward. This also causes new resin to flow, replacing the resin polymerized on the green body. This resin flow can push polymer chains into the network, which can force the chains to align and prevent them from reaching their lowest possible energy state. A slower rate of pulling reduces the adhesive force acting on the construction plate as it is pulled. This also reduces the rate of the newly replacing resin flow. This, in turn, increases the amount of time the new resin is exposed to radiation. If the reactivity of the resin is also reduced, for example by reducing the amount of photoinitiator, it will take longer for the resin to polymerize into the final network. This excess time allows for higher mobility of polymer chains in the network as it forms, which gives them a greater opportunity to find their lowest energy state. In one embodiment, the present invention provides an optical lens produced by sustained tank polymerization, achieving a relaxed network.In one embodiment, the present invention provides a method of sustained tank polymerization in which the pulving speed is coordinated with the reactivity of the resin and limits the stress from chain matching.

[0097] In addition to the general mechanical benefits of the directional aspect of polymer networks, optical lenses have a wide range of potential applications. One major potential application is lens polarization. Typical lens polarization is achieved by applying a coating to a lens or between two lenses. This coating is a vinyl coating having a network of polarizing molecules set on it, such as a hydrocarbon coated with crystals. Once assembled, the polarizing network is typically aligned in a specific direction through the use of charges flowing through a film to match the polar molecules of the network. This network is aligned in such a way that only light parallel to the direction of the network's alignment can pass through the lens. Typically, these coatings are applied to tinted eyeglasses or sunglasses, and they limit glare, i.e., the amount of light originating from a specific direction. Typical polarizing filters have a network that is vertically aligned so that horizontal waves of light are blocked. This coating limits the amount of glare perceived when looking through the lens. Polarization can be provided to optical lenses without the use of coatings, using the directional properties provided by the sustained DLP tank polymerization process. In one embodiment, a directional, additively manufactured optical lens or additively manufactured optical component precursor further comprises a polarizer, the polarizer being matched to the directionality of the optical lens or optical component precursor. Suitable polarizers include, but are not limited to, tourmaline, iodine, silver, helapatite, crystal-coated hydrocarbons, and equivalents.

[0098] Another potential application is the use of liquid crystals. In the manufacture of optical materials, liquid crystals are typically used to modify the light transmittance of a material. They are common polarizers in many different types of optical lenses, and they have additional potential beneficial properties. In addition, liquid crystals are used to modify the intensity of lenses. To achieve this, polar liquid crystals are suspended between two layers of light-transmitting material. When an electrical charge is applied to these liquid crystal layers, their orientation changes, and the optical properties of the optical material also change. Examples include standard LCD screens, smart windows that change the amount of light passing through them, and liquid crystal lenses with various benefits. One benefit of liquid crystals is their ability to change the intensity of a lens. By aligning to a certain orientation, the light passing through the lens becomes either more dispersed or more focused, resulting in a change in the intensity of the lens. Liquid crystals in a lens can change their orientation when a charge is applied through them in a given direction, which can cause a change in the curvature of the lens, and therefore a change in spherical power. This is an option for users who desire correction for both nearsightedness and farsightedness but do not desire lenses with multiple spherical powers at any given time. In one embodiment, the resin formulation for the additive manufacturing of optical lenses includes liquid crystals. The directivity within the network of optical lenses, provided by a sustained tank polymerization process, can be aligned in a direction within the lens itself without the need for additional processing steps to add them, thus enabling the benefits of liquid crystal lenses.

[0099] In addition to the inherent directional and general advantages of additive manufacturing, sustained tank polymerization offers additional benefits to the field of optical lens manufacturing. One advantage is the diverse material properties that sustained tank polymerization can provide. Typical tank polymerization manufacturing involves post-printing treatment of the article after it has been removed from the printer, but before the final product is achieved. This post-printing treatment of the article, also known as the “unformed” article, after printing is complete, but prior to the completion of post-printing treatment, often involves further curing outside the printer. This additional curing can ensure that all the resin in the unformed product is completely polymerized and 100% curing is achieved. Often, this curing involves both UV curing and thermal curing via a thermal initiator present in the initial resin formulation. Even if UV curing can occur during both the printing process and post-printing treatment, UV curing during post-printing treatment differs because it typically involves the use of a lamp that administers UV light only to the surface of the unformed article.

[0100] It has been found that altering the ratio of total curing that occurs during the printing process to curing that occurs during the post-printing process can alter the material properties of the solidified resin. In one embodiment, a given article printed using a given resin formulation that is 50% cured during the printing process and 50% cured during post-printing treatment will have different material properties compared to the same article printed using the same resin formulation that is 20% cured during the printing process and 80% cured during post-printing treatment. This is due to differences in polymerization reactions that occur during the various stages of the printing process. Polymerization proceeds either via chain extension or crosslinking, and different types of curing can provide different ratios of chain extension and crosslinking within each article printed with a given resin formulation. These different ratios can result in significant differences in mechanical properties across a single article and / or multiple articles printed with a given resin formulation. In some embodiments, articles printed with a given resin formulation having a higher ratio of crosslinking to chain extension have higher mechanical hardness compared to articles printed from the same resin formulation having a lower ratio of crosslinking to chain extension. In some embodiments, the lower the degree of curing of a given resin formulation on the printer compared to after printing, the greater the degree of crosslinking present in the polymer network of the solidified resin in the final article. In some embodiments, articles printed with a given resin formulation having a higher ratio of crosslinking to chain extension have a more relaxed polymer network than polymers formed from resin formulations having a higher ratio of crosslinking to chain extension.

[0101] Several aspects of the additive manufacturing process can be modified to alter the curing percentage at different stages of the manufacturing process. Exemplary aspects, but not limited to, include, among others, light intensity, curing temperature, printing speed, the amount of light and / or thermal initiator present in the resin formulation, the time exposed to light and / or heat during post-processing, and temperature control during the printing process. Through experiments with a given resin formulation, articles with a wide variety of mechanical properties can be produced by modifying these aspects of the sustained tank polymerization additive manufacturing process. In addition, a given article undergoing a given printing process can have different mechanical properties at different points within its geometry. During the printing process, 3D pixels, known as voxels of the resin, must accept a certain amount of energy to polymerize completely. This polymerization can take the form of either chain extension or crosslinking, where chain extension is done so as not to impart further elastomeric material properties, and crosslinking is done so as not to impart further rigid material properties. By altering the amount of chain extension and crosslinking across the voxels of an article, different mechanical properties can be imparted across a single part of the article from a single additive manufacturing process.

[0102] As a method of controlling mechanical properties, modifying the ratio of chain extension to crosslinking is not available in layer-by-layer techniques. In layer-by-layer techniques, curing is stronger at the bottom of each layer compared to the top, leading to heterogeneous properties in the article. In addition, articles manufactured using layer-by-layer techniques have weak interlayer connectivity, and therefore the network is not homogeneous. A truly homogeneous network is required to appropriately modify mechanical properties through changes in curing ratio and printing process. In addition, proper control of the curing ratio requires temperature-controlled measurement during the printing process. A significantly higher degree of control over these ratios is available in resin formulations equipped with thermal initiators. Articles printed using these resins undergo additional thermocuring after the printing process is complete. In some embodiments, thermocuring induces more significant crosslinking with respect to articles printed using a given resin formulation compared to articles cured using radiation alone. The exothermic polymerization reaction occurring during the printing process can release enough heat to induce this thermocuring, which can modify the network of the polymerizing resin. Continuous tank polymerization techniques, such as those using temperature control mechanisms like HARP, are uniquely preferred over other techniques because they can generate a homogeneous polymerization network and better control the curing ratio, thus enabling more significant control over the polymerization network and, consequently, the properties of the final product.

[0103] In the field of optical lens manufacturing, the ability to control polymerization networks can offer unique advantages. In conventional optical lens manufacturing, a given material has given optical properties, and material selection must be based on the desired lens properties. As a result, optical lens manufacturers must have access to multiple different materials to produce lenses for a wide variety of users. On the other hand, manufacturing optical lenses using sustained tank polymerization makes it possible to produce optical lenses with various optical properties using fewer resin formulations. A method for manufacturing lenses that correct both low-order and higher-order aberrations.

[0104] One embodiment demonstrates an increase in the Abbe number through the geometric shape across a sheet of material, as defined in accordance with ASTM specifications.

[0105] In one embodiment, the two lenses may have the same spherical and cylindrical powers, which are derived from the same inner and outer surface powers as well as the same diameter and center thickness. When all these factors are equal, a lens manufactured by additive manufacturing according to the embodiments described herein, which is designed to eliminate higher-order aberrations, will have higher-order aberrations than a lens manufactured using conventional manufacturing methods.

[0106] There are two sets of aberrations that cannot be resolved by current manufacturing methods. Current manufacturing methods cannot provide high-quality surface texture and resolution while maintaining the required smoothness for optical surfaces up to a certain threshold.

[0107] The first type of aberration is dispersion, a property of the material; the Abbe number is derived from the combination of this material property and its geometric shape. The second type is non-uniformity of the sensor itself. Designing for both gives the sensor a more accurate part image (in the case of ophthalmology, such design is related to the geometric shape of the eyeball).

[0108] In some embodiments, altering the ratio of chain extension to crosslinking in the homogeneous network of an optical lens additively manufactured using a given resin formulation will change the refractive index of the final optical lens. In some embodiments, altering the ratio of chain extension to crosslinking in the homogeneous network of an optical lens additively manufactured using a given resin formulation will change the Abbe number of the final optical lens. In some embodiments, a polymer network having a higher ratio of crosslinking to chain extension can have a higher refractive index as a result of the increase in crosslinked polymer refracting light to a greater extent than a lower amount of crosslinked polymer. In addition, different regions of the lens undergo different curing ratios and therefore different optical properties can be achieved throughout a single lens. In some embodiments, the additively manufactured lens is formed using sustained tank polymerization, having a non-uniform refractive index. In some embodiments, the optical lens is a bifocal lens, where the refractive index and Abbe number at the bottom of the lens differ from the refractive index and Abbe number at the top of the lens. In one embodiment, the optical lens is a progressive lens in which the refractive index and Abbe number are varied throughout the lens in order to achieve different spherical powers in different regions of the lens. This can be done by having a varying ratio of chain length and bridging throughout the lens, and thus modifying the optical properties of the lens at a given point. Optical lens precursor

[0109] In lens geometry, a lens must have the required shape in order to provide correction and to be able to fit into a desired frame. 3D printing makes it possible to manufacture optical lens precursors that are identical or substantially similar to the desired final shape of the lens. This differs from conventional techniques, where the lens raw material typically needs to have a radius that is twice that of the radius between the optical axis and the edge of the lens of the final lens. In addition, the lens raw material is perfectly round and thicker than the final optical lens to allow the raw material to be molded to fit into a selected frame. As a result, the volume of material used for the lens raw material is more than twice the volume of material present in the final optical lens. In one embodiment, the present invention provides an optical lens precursor that uses less than twice the volume of material present in the final desired optical lens. In one embodiment, the 3D printed optical lens precursor uses a material that is 60.0% or 50.0% or 40.0% more, 30.0% more, 20.0% more, 15.0% more, 10.0% more, 5.0% more, 4.0% more, 3.0% more, 2.0% more, 1.0%, or 0.5% more than the desired final optical lens. In other embodiments, the 3D printed optical lens precursor uses material that is 1.0% to 50.0% larger in volume than the desired final optical lens, or 3.0% to 50.0%, 4.0% to 50.0%, 4.0% to 40.0%, 5.0% to 40.0%, 5.0% to 30.0%, 10.0% to 50.0%, 10.0% to 40.0%, 20.0% to 50.0%, or 20.0% to 40.0% larger. In one embodiment, the optical component precursor uses material that is approximately the same volume as the desired final optical lens.

[0110] An additional benefit of using additive manufacturing is that the optical lens precursor can also be printed smaller than the desired optical lens. This would allow the optical lens precursor to be coated with refractive index matching material to achieve the desired final dimensions, thickness, and smoothness. In one embodiment, the 3D printed optical lens precursor is at least 5.0% smaller than the desired final optical lens, at least 4.0% smaller than the desired final optical lens, at least 3.0% smaller than the desired final optical lens, at least 2.0% smaller than the desired final optical lens, at least 1.0% smaller than the desired final optical lens, at least 0.5% smaller than the desired final optical lens, at least 0.1% smaller than the desired final optical lens, at least 0.01% smaller than the desired final optical lens, and at least 0.001% smaller than the desired final optical lens. An exemplary optical lens precursor is considered to be substantially the same size as the final desired optical lens when its volume is within 90.0% to 110.0%, more preferably 95.0% to 105.0%, more preferably 97.0% to 103.0%, more preferably 98.0% to 102.0%, and more preferably 99% to 101% of the final desired optical lens volume. This allows 3D printed optical lenses to produce significantly less waste and reduce processing time compared to conventional lens manufacturing using raw lens materials. In one aspect, the present invention provides an additively manufactured optical component precursor comprising an optical lens precursor that is substantially the same size as the desired final optical lens.

[0111] Printing optical lens precursors that are customized for individual users and as close as possible to the desired geometric shape of the desired final optical lens becomes more important as eccentricity occurs. Eccentricity occurs when the user's interpupillary distance (PD), i.e., the distance between the user's pupils, differs from the frame's interpupillary distance (FPD), i.e., the distance between the mechanical axes of the lenses within the frame. This necessitates differentiation between the optical axis and the mechanical axis of the lens during manufacturing. When eccentricity is considered using conventional manufacturing techniques for lens raw materials, the lens raw material used must be twice the difference between the PD and the distance between the frame centers. For example, if the difference between the user's PD and the distance between the centers of their desired frames is 2 mm, the minimum possible lens raw material must be at least 4 mm larger than if there were no difference between the PD and the distance between the frame centers. On the other hand, 3D printed optical lens precursors do not need to increase in size when eccentricity occurs. Instead, eccentricity can be taken into account, and the portion of the optical lens precursor that will become the optical axis of the final optical lens can be moved when generating the CAD of the optical lens precursor to be printed, without requiring an increase in the size of the optical lens precursor. This further reduces the time used and the waste produced during the processing of the optical lens precursor.

[0112] product In addition to improvements in general optical lenses and optical lens manufacturing processes, sustained tank polymerization makes it possible to develop unique products that would otherwise not be available with conventional optical lens or stereolithography manufacturing techniques. In one aspect, the present invention provides the capability for the simultaneous additive manufacturing of frames and lenses. In another aspect, a method utilizing the present invention makes it possible to print optical lens precursors and / or optical component precursors simultaneously with the associated frame. In one embodiment, a single resin formulation is used to form both the optical lens precursor and / or optical component precursor and the associated frame. In one embodiment, a suitable 3D printer is capable of holding at least two independent resin formulations, one used for the optical lens precursor and / or optical component precursor and the other used for the associated frame. In one embodiment, this is carried out through a resin tank having separate compartments for the different resin formulations. In one embodiment, a suitable 3D printer comprises an attachment that can be installed in the resin tank, capable of keeping the two resin formulations separate. The two lenses are fabricated together as a single component.

[0113] In some situations, the prescription may differ for each patient's eye. In addition, each eye center may have a relative distance to the center of the other eye from the center of the tissue and / or the center of the face.

[0114] The lens has a connector to which the side of the frame hardware is attached.

[0115] In general, visors, goggles, and gas masks may be formed to accommodate different eye prescriptions and different ocular centers, according to the embodiments. Such embodiments are described in more detail below (see, for example, paragraphs 75-82 below).

[0116] In one aspect, the present invention provides a single additively manufactured optical component, the optical component further comprising at least two optical lens precursors. In another aspect, the present invention provides an additively manufactured spectacle article, manufactured as a single piece using a single resin formulation. In another aspect, the additively manufactured spectacle article further comprising at least one optical lens precursor and an associated frame. In one embodiment, both the optical lens precursor and the associated frame are printed from a single resin formulation. In one embodiment, the optical lens precursor and the associated frame have different crosslinking and chain extension ratios within their polymer networks, allowing the frame and lens to have different mechanical properties despite being constructed from the same resin formulation. In one embodiment, at least one optical center of the lens differs from the geometric center of the associated frame. In one embodiment, the optical lens precursors have different powers. This is accomplished by exposing the optical lens precursor and the frame to different amounts of energy during the printing process, which will affect the percentage of curing, and therefore the crosslinking and chain extension ratios, that occur on the printer. In some embodiments, the frame of an additively manufactured spectacle article further comprises one or more periphery portions that fluidly communicate with the edges of optical lens precursors and adjacent portions between optical lens precursors. In some embodiments, adjacent portions further comprises one or more bridge regions that connect to the periphery portions surrounding the optical lens precursors, designed to rest on the bridge of the nose when the frame is fitted. In some embodiments, the frame of an additively manufactured spectacle article further comprises two or more end portions, two or more end portions being integral with the periphery portions that extend away from the center of the spectacle article. In some embodiments, each of the two or more end portions further comprises a hinge. In some embodiments, the hinge is detachably coupled to an arm portion that extends away from the spectacle article. In some embodiments, the hinge is capable of moving the arm portion up to 90 degrees. In some embodiments, the hinge is capable of moving the arm portion up to 120 degrees.In one embodiment, the additively manufactured eyeglass article further comprises an arm piece formed integrally with a hinge during the additive manufacturing process. In another embodiment, the additively manufactured eyeglass article comprises an arm piece formed integrally with an end piece without the need for a hinge. In one aspect, the present invention provides a fully formed eyeglass article comprising a frame and an optical lens precursor, which are additively manufactured as a single-piece article. In one embodiment, the frame further comprises coupling means. In another embodiment, the additively manufactured eyeglass article further comprises an outer frame component which is coupled to the frame via the coupling means. The coupling means, present in the frame, would allow the frame to be bonded to the outer frame component. The coupling means would allow the additively manufactured frame to be coupled to a second frame piece via the coupling means. This would allow overcoming the aesthetic problems (i.e., color) that may arise from the additively manufactured frame being constructed from the same resin formulation as the lens. In addition, this would allow for further customization of the frame by the end user by having multiple colors of the outer frame component which can be easily coupled to and detached from the additively manufactured eyeglasses. Suitable coupling means include, but are not limited to, magnets, latches, hinges, and equivalents.

[0117] The present invention enables the production of fully functional eyeglasses using a single additive manufacturing process, which has numerous benefits, including complete customization for the end user in terms of both optical lenses and frames, reduced waste, fewer processing and fittings required for lenses within frames, and reduced inventory required on hand to make eyeglasses to order. In addition, the present invention enables the production of eyeglasses except for any structural features of the frame, allowing the frame components to be fitted at any later stage of production. This would include printing optical lens precursors and peripheries, and enabling customization of bridges, end pieces, hinges, arm pieces, other components of eyeglasses, or any combination thereof.

[0118] In one aspect, the present invention provides additively manufactured progressive refractive optical lenses having varying spherical and cylindrical powers throughout. Progressive refractive optical lenses are defined as lineless multifocal lenses, meaning they are optical lenses that have varying spherical powers throughout the entire lens. Typically, these lenses have two or three regions with different spherical powers from each other, allowing for the correction of multiple vision problems using a single lens. A typical shape of the spherical power of a progressive refractive lens is hourglass-shaped, where the upper part of the lens has a negative spherical power and corrects myopia, the middle region in the center, i.e., the progressive refractive corridor, has a varying spherical power that becomes more positive towards the bottom of the lens, and the bottom of the lens has a positive spherical power and corrects hyperopia. Progressive refractive lenses also have a “hybrid region” that arises from both periphery of the lens. This hybrid region allows the user to gradually adjust their vision as their eye moves from the top of the lens, through the corridor, to the bottom of the lens, or vice versa. This is done through the use of different levels of cylindrical power, which become more positive as the hybrid region approaches the bottom of the lens. This cylindrical power is necessary to eliminate distinctly different lines of correction change in the lens. However, the fluctuating cylindrical power often causes a blurred, astigmatism-like visual aberration because the cylindrical curvature focuses the image on a plane rather than a point, as in the case of a spherical lens. This is true both when the cylindrical power is too strong and too weak for the user's correction needs. Increasing the size of the hybrid region can reduce this blur because the cylindrical power can become weaker, but this comes at the cost of reducing the size of the top and / or bottom regions of the lens. Alternatively, the size of the upper and / or lower regions of the lens can be increased, resulting in a lens with a stronger cylindrical power in the mixed region, and therefore increased blur.

[0119] In some embodiments, progressive lenses can be achieved by manufacturing one or both of the curved surfaces separately from the lens itself. In some embodiments, progressive lenses are formed by directly additively manufacturing a curved structure on a pre-formed lens. Additive manufacturing is uniquely positioned to convert a general-purpose pre-formed lens into a progressive lens by manufacturing only a unique curvature that causes the lens to progressively refract and attaching that curved surface to the pre-formed lens. In some embodiments, the additively manufactured progressive surface is attached to the pre-formed lens during the 3D printing process. In some embodiments, the additively manufactured progressive surface is attached to the pre-formed lens during post-processing.

[0120] Conventional optical lens manufacturing techniques produce a raw lens with variable spherical power on one surface, and then the other surface is shaped to adapt to the specific user's corrective needs. This technique makes it difficult to truly customize the lens to the user's corrective needs, limiting the availability of freely customizing the lens power, fit, material, and frame. This can result in compromises in vision, particularly at the periphery of the lens and for users with astigmatism. This becomes a more significant problem as eccentricity occurs, limiting the choice of frames that can be used with progressive lenses. In addition, free-form molding techniques have been developed, allowing for the customization of both the front and back surfaces of progressive lenses, more effectively and completely customizing the user's eyewear and increasing their vision. However, these lenses are expensive to produce and take significantly longer than molding only one side of the lens. Additive manufacturing allows for the production of progressive lenses in the same manner as any other lens, with a full spectrum of customization options for different aspects of the available lens. All aspects of progressive lenses can be customized to meet the specific needs of the user. This can be achieved by directly printing the optical lens precursor of the progressive lens from the CAD of the desired lens, thus eliminating unnecessary manufacturing steps and enabling complete lens customization.

[0121] In one aspect, the present invention provides additively manufactured periwrapping optical lenses. In another aspect, the present invention provides additively manufactured periwrapping optical lens precursors. Periwrapping lenses are desired for additional protection compared to conventional eyeglasses, and they provide protection against light and foreign objects directed outward from the eye. Typically, periwrapping lenses are useful for eyeglasses, intended to be worn during an activity cycle or as protection for users suffering from eye-related conditions. Non-limiting embodiments include periwrapping sunglasses, motorcycle eyeglasses, and athletic eyewear (goggles, protective and / or corrective lenses worn during competition, etc.). Current manufacturing techniques for periwrapping lenses are limited in terms of spherical power. The need for additional curvature to provide protection for periwrapping lenses also limits the spherical power capability of these lenses. Typical periwrapping lenses have a spherical power range of -6.00 to +4.00. In addition, typical periphery-wrapped lenses have cylindrical powers ranging from -2.00 to +2.00. Users with prescriptions outside this range will struggle to adjust periphery-wrapped lenses manufactured using conventional optical lens manufacturing techniques. This is due to the selection of raw lens materials based on the frame, not the user's ophthalmic prescription. The desired frame is selected, and then the raw lens material is selected based on the frame's curvature. This limitation prevents conventional optical lenses manufactured using raw lens materials from correcting high-intensity prescriptions in periphery-wrapped lenses.

[0122] The sustained tank polymerization technique can produce optical lens precursors that satisfy both the frame curvature requirements and the user's correction requirements, thus enabling the manufacture of peri-wrapped lenses that overcome this limitation. In one aspect, the present invention provides additively manufactured peri-wrapped optical lenses. In another aspect, the present invention provides additively manufactured peri-wrapped optical lenses having spherical powers outside the range of conventional optical lens manufacturing techniques.

[0123] In one aspect, the present invention provides an additively manufactured optical component precursor comprising a single-piece optical region, the single-piece optical region spanning a distance sufficient to provide optical capability across both of the user's eyes. In another aspect, the present invention provides an optical component precursor comprising a single piece having two independent optical regions. Similar to wrap-around lenses, conventional optical lens manufacturing techniques have limitations when producing single-piece optical lenses that span both eyes. This type of optical lens plays an important role in protective eyewear. Non-limiting embodiments of this type of lens include, but are not limited to, ski goggles, laboratory goggles, and gas masks. To effectively manufacture these optical lenses using conventional techniques, the raw material must be specifically fabricated to fit the shape of the frame of these lenses, which often has a very unique geometric shape specific to their functionality. Additive manufacturing can adapt these unique geometric shapes using the same techniques they would use to manufacture any other optical lenses.

[0124] Printing on parts The embodiments provide a method for additive manufacturing on another product. Such embodiments are applicable only to liquid interface printing, as such printing allows the part to be immersed in the interface to enable formation around the part. Further embodiments may benefit from an array having multiple projectors. Such an array preferably ensures a uniform distribution of intensity around the object.

[0125] The apparatus, which includes multiple projectors angled relative to the component, not only allows the component to be printed onto optical waveguides, stock lenses, and electronic devices, but can also allow the printed component to be formed from different materials. Aspects of these embodiments are described in further detail in the following paragraphs.

[0126] In one aspect, the present invention provides an additively manufactured optical lens comprising an electronic component. In another aspect, the present invention provides an additively manufactured optical component precursor comprising an electronic component. In one embodiment, the electronic component is partially optically transparent. In one embodiment, the optically transparent electronic component further comprises at least one display capability. In one embodiment, the optically transparent electronic component further comprises at least one eye-tracking capability. Additive manufacturing is uniquely positioned to manufacture optical lenses having electronic components, often referred to as “smart glasses.” Typical smart glasses manufacturing requires an additional processing step in which the electronic component is added between two lenses or otherwise placed on the surface of the lenses. On the other hand, additive manufacturing techniques can place or adsorb the electronic component onto a construction surface and print an optical lens around the electronic component using any suitable additive manufacturing technique. In addition, additive manufacturing methods with a cooling aspect, such as HARP technology, can more effectively account for temperature changes that may occur during the printing process, which can mitigate temperature-related changes to the electronic component. Furthermore, the use of liquid printing interfaces such as HARP allows electronic components to be immersed in the interface, which provides more manufacturing freedom around the electronic component than is available using solid interfaces. In one embodiment, the electronic component comprises a waveguide display. In another embodiment, the electronic component is an augmented reality display. In yet another embodiment, the electronic component is a virtual reality display. In one embodiment, the optical lens having the electronic component is an ophthalmic lens.

[0127] Sustained tank polymerization may also have advantages when manufacturing optical components other than eyeglasses. In one embodiment, the present invention provides additively manufactured higher-order lenses. In one embodiment, the additively manufactured higher-order lenses are substantially aberration-free. Additive manufacturing makes it possible to eliminate higher-order monochromatic aberrations through microscopic modifications to the surface structure of the lens in order to correct undesirable reflection or refraction of light. In one embodiment, the additively manufactured higher-order lenses are telescopic lenses. In one embodiment, the additively manufactured higher-order lenses are microscopic lenses. In one embodiment, the additively manufactured lenses are transparent to infrared radiation.

[0128] Method of sustained tank polymerization In one aspect, the present invention provides a method for producing optical components via additive manufacturing. In another aspect, the present invention provides a medium for controlling a sustained-tank polymerization apparatus to carry out a method for forming optical components. In another aspect, the present invention provides a method for producing one or more optical components via additive manufacturing. In one embodiment, a CAD of an optical component is generated based on optical data, and then an image stack is generated based on the CAD, such that a radiation source will determine how energy will be emitted and selectively curing the resin formulation. A resin formulation suitable for optical lens manufacturing will then be selected and placed in a resin tank of a sustained-tank polymerization 3D printer. The radiation source will then sequentially emit patterned energy into the resin in the tank, determining the polymerization of the resin based on the image from the image stack, while the solidified resin is sustainably drawn away from the radiation source. This step will be repeated until an unformed product of the optical component precursor is formed. The unformed product of the optical component precursor will then undergo post-printing treatment, which at least in some aspects includes further curing of the unformed product outside the 3D printer until the unformed product achieves 100% polymerization and the optical component is formed. In some embodiments, the optical component further comprises at least one optical lens precursor. In some embodiments, the optical component further comprises at least one optical lens. Support device and component design for anti-reflective ("AR") coating systems

[0129] Some of the embodiments may include adhesive zone support structures; see, for example, Figure 25-29 and the corresponding sections of the specification.

[0130] Further embodiments may include a removable and bondable construction step with an etched identifier. Such an etched identifier may be used to identify the optical component during processing. Such exemplary construction steps may be accompanied to the optical component through post-processing, including the application of an AR coating.

[0131] In some embodiments, the optical components are bonded to the construction stage via an adhesive zone until post-processing is complete. Such adhesive zone support structures may support the optical components through spin coating and immersion coating. Following the removal of the construction plate and adjacent optical components from the AR coating apparatus, the construction plate and adjacent optical components may remain bonded during vapor coating.

[0132] In one embodiment, a solid wall support structure may be used.

[0133] Solid wall support structures may include a consistent geometric shape across multiple optical components, thereby enabling their use as a base for any optical component design. A single solid wall support structure size may be sufficient to support both small and large lenses using the same solid wall support structure design. See reference. Such solid wall support structures may be ideal for vapor coating because both surfaces are exposed to vapor, but an airtight seal is created between the surfaces by the solid wall. See reference.

[0134] This involves the design of a support structure and an AR coating holder. In embodiments, the support structure may be modified to receive the lens using a support. Two conventional sides of the AR coating holder exist, one side having a ring that directly touches the lens, and the other side having an array that holds all the rings, and embodiments of the present invention can work to improve both sides. See therein.

[0135] In some embodiments, the optical component precursor further comprises a support structure capable of supporting the optical lens precursor during at least one post-printing step. In some embodiments, the optical component precursor further comprises at least one frame piece, the frame piece being integrally formed with the optical lens precursor or optical lens. In some embodiments, the frame piece further comprises at least one periphery, the periphery being integrally formed with and surrounding at least one of the optical lens precursors or optical lenses. In some embodiments, the frame piece further comprises at least two optical lens precursors or optical lenses. In some embodiments, the frame piece further comprises an adjacent piece, the adjacent piece being integrally formed with at least one periphery. In some embodiments, the adjacent piece further comprises a nose bridge. In some embodiments, the frame piece further comprises at least one end piece, the end piece being integrally formed with at least one of the periphery. In some embodiments, the frame piece further comprises at least one arm piece, the arm piece being integrally formed with at least one end piece. In some embodiments, at least one end piece further comprises a hinge. In some embodiments, the hinge is integrally formed with at least one arm piece. In some embodiments, the frame piece further comprises coupling means, allowing the frame piece to be attached to an outer frame component. In some embodiments, the image stack is generated directly from optical data. In some embodiments, the optical data further comprises the type of optical lens, an ophthalmic prescription defining at least one refractive component of the lens, the resin formulation to be used, the dimensions of the optical lens, the frame shape, or a combination thereof.

[0136] radiation source In some embodiments, aberrations caused by the projector may be eliminated. Such embodiments may involve Mie and Raleigh scattering, as described in further detail in paragraph 113. In some embodiments, as described in further detail in paragraph 112, refractive index matching with oil may be used to ensure that there is no change in IR as the radiation passes from the interface into the resin.

[0137] Moving components relative to the projector can also reduce or eliminate aberrations caused by the projector, as will be described in more detail in paragraphs 104-105. Such movement may be implemented using a conveyor belt or other suitable mechanism.

[0138] Collimated light sources may also be used to reduce aberrations caused by the projector, as described in more detail in Figures 5 and 6 and the corresponding sections of the specification.

[0139] Other devices that may be used to reduce aberrations caused by the projector may include using multiple radiation sources to stop the resin from over-curing when it is removed from the resin bath. Such embodiments are described in further detail in exemplary paragraphs 100-101.

[0140] Similarly, a liquid that sits on the resin, either pushing away the uncured resin or matching the refractive index of the cured part, may be used to stop internal reflections.

[0141] In one embodiment, the sustained vat polymerization around the electronic component further comprises the use of multiple radiation sources. In one embodiment, the projected area of ​​each radiation source encloses the entire geometric shape of the electronic component. This ensures uniform polymerization of the material around the entire electronic component.

[0142] In addition to general sustained tank polymerization techniques, the present invention provides specific techniques for sustained tank polymerization of optical lenses and optical lens precursors. Specifically, the present invention provides techniques for overcoming challenges specifically related to the sustained additive manufacturing of optical lenses. In one embodiment, the radiation source further comprises a DLP projector. The DLP projector utilizes an array of digital micromirror devices (DMDs) to enable the precise projection of light in a pattern for precisely curing the resin into a desired 3D structure. In sustained tank polymerization, energy from the DLP projector is reflected from the array of DMDs into the resin formulation. The pattern is determined by whether each mirror in the array is on or off, thus allowing control of the pattern of energy emitted from the projector. A current limitation of DLP projectors used in 3D printing is the space between DMDs within the individual semiconductor chips of the projector. In an exemplary DLP projector, these spaces are approximately up to 3 μm in length. In an exemplary DLP projector, these spaces are approximately 1 μm long, and each mirror in the array has a pitch of approximately 5.4 μm, i.e., the distance from the center of one mirror to the center of the adjacent mirror. As energy from the semiconductor chip passes through the lens of the DLP projector and expands outward, these microscopic spaces can lead to an inconsistent degree of solidification of the polymerizable resin, resulting in stress zones on the surface of the additively manufactured article. While these stress zones are imperceptible in most articles, they can cause imperfections in the refraction of light and perceptible aberrations within the lens. The microscopic spaces between DMDs worsen as the projected area of ​​radiation expands. In one embodiment, a 3-micron gap between pixels becomes 5 microns within the projected area of ​​radiation. This expansion causes radiation from the projector to reach the polymerizable resin at a certain outward angle. This can lead to inconsistent curing because the center of the projected area receives increased radiation compared to the edges, resulting in stress zones that appear in the area receiving a larger amount of radiation.

[0143] Techniques exist that can overcome this limitation in both individual projectors and projector arrays. In some embodiments, the DLP projector further comprises a rotating component that allows the DLP projector to rotate freely throughout the printing process. An exemplary preferred rotating component would be a rotary actuator. Rotating the optical projector throughout the printing process can more uniformly distribute the energy from a given projector across the entire projection area of ​​the projector and mitigate the effects of gaps between DMDs. In some embodiments, the DLP projector further comprises a vibrating component that more uniformly distributes the intensity of radiation across the projection area of ​​the projector.

[0144] In one embodiment, emitting a sequential pattern of light from a DLP projector further includes emitting a sequential pattern of light from a DLP projector that is intentionally defocused. Intentionally defocusing, or "blurring," the projector can mitigate the effects of gaps between DMDs. This blurring effect allows intersections between the projection areas of individual DMDs, thus mitigating the effects of these gaps and effectively eliminating seam lines. As a result of this blurring, a certain amount of precision on the edges of the unformed product is lost, which can result in roughness in the edge geometry of the unformed product. However, most unformed products and all optical lenses undergo some form of post-printing polishing and / or edge finishing, which can effectively eliminate this roughness. Blurring can be carried out in a variety of ways. A DLP projector typically includes at least one focusing lens, which is calibrated to a specific focal length based on the size and focus of the DMDs in the projector. In one embodiment, a DLP projector has a given pixel size, which is generated by energy reflected from individual micromirrors, each micromirror independently contributing to the energy of one pixel. When one or more focusing lenses are "in focus," the pixel size is precisely specified by the projector's optimal parameters. In one embodiment, a projector suitable for 3D printing has an optimal pixel size of 72 microns. Once the pixels achieve the optimal size based on the projector's parameters, the light from the projector travels a certain distance from the projector, which is the projector's focal length. By moving the focusing lens, the DLP projector can be blurred by intentionally altering the focus, which means that the pixel size at a given focal length has changed. Typical alignment and focusing of a projector utilizes a camera system located at a discrete distance from the projector. Due to its discrete distance from the projector, this camera can ensure that the optimal pixel size and focal length are achieved when the projector's lens is focused.In one embodiment, intentional defocusing of a projector involves moving a camera to a discrete distance such as toward or away from the projector, and then adjusting one or more focusing lenses on the projector so that the camera perceives the projector as being in a "focused" state. This method allows a discrete "degree of blur" to be grasped and therefore controlled. In one embodiment, intentionally defocusing the projector so that the focal length exceeds that when it is in focus causes overlap of radiation emitted from each micromirror in the DMD array. This method of intentional defocusing will provide a controllable and measurable method for mitigating the adverse effects of space between micromirrors, as it allows for a meaningful change in pixel size without a meaningful change in projection area.

[0145] An additional method of intentional defocusing is the use of X and Y direction movement in addition to Z direction movement during the printing process. In some embodiments, lateral movement of the product reduces the angle at which radiation arrives at the polymerizable resin, which can eliminate stress zones caused by outward expansion of the projected area. This also allows the product to be cured by multiple pixels in a projector or projector array, which ensures a more uniform application of radiation into the product. In some embodiments, lateral movement of a 3D product includes each voxel of the 3D product being cured by multiple pixels of one or more projectors as the 3D product is moved laterally. Preferred non-limiting embodiments of methods for moving the product during manufacturing include robotic arms and conveyor belts. A device for drawing out the normal of a curved surface (inner surface, outer surface, or inner center) at the vertical center line of a lens, such that the normal to the curved surface is perpendicular to the interface.

[0146] One embodiment may include a robotic arm or other robotic device attached to the construction surface. Such a robotic device is preferably capable of moving the construction surface in 360 degrees of freedom. The controller of such a robotic device may move in a curved motion that conforms to the curved surface of the lens being manufactured. Such an embodiment can ensure that the normal to the curved surface is perpendicular throughout the entire process.

[0147] In one embodiment, the product is moved in a curved path during the manufacturing process. The curved movement of the product can be used to help shape the optical components. In addition, this limits the amount of under-curing or over-curing by allowing only the area undergoing polymerization to be aligned with the radiation. Over-curing and under-curing occur when radiation reaches the partially cured, unformed product beyond the polymerization interface. When attempting to account for, or failing to account for, radiation passing through the unformed product, over-curing or under-curing may occur, which prevents achieving the desired degree of polymerization from the printing process. The curved path of the unformed product will provide greater control and specificity across the area of ​​the unformed product affected by radiation at any given time during the manufacturing process. In one embodiment, the normal of the curved surface of the lens remains perpendicular to the interface throughout the entire manufacturing process.

[0148] In one embodiment, the product remains fixed in the X direction, while the projector moves instead.

[0149] Intentional defocusing can also be performed using an array of projectors. In one embodiment, the radiation source further comprises an array of projectors. In one embodiment, the projection area of ​​one of the projectors in the array overlaps with the projection area of ​​another projector by half a pixel. By doing so, the gaps between DMDs within each projector are taken into account by the other projectors, and the intensity is uniformly distributed across the combined projection area. Apparatus for collimated projection sources of rigid masks

[0150] In one embodiment, a microactuator may be used to match an SDF file interval and directly use that file for position data.

[0151] In an alternative embodiment, the DLP projector further comprises a rigid mask. The rigid mask physically shapes the radiation from the projector by blocking all emission except for a desired shape. In one embodiment, the mask further comprises a controller, which determines the movement of a plurality of linear actuators, which are coupled to a bladder. In one embodiment, the number of linear actuators is equal to the number of dots in a dot array on an .sdf file.

[0152] In one embodiment, each linear actuator aligns with a dot in the dot array. Each linear actuator achieves depth in the X direction, which shapes the bladder and conforms to the desired curved surface of the lens. The radiation is then continuously emitted, and the linear actuators move the bladder, maintaining the shape of the dot array throughout the manufacturing process.

[0153] Intentional defocusing, or blurring, is not without its negative aspects. Blurring causes imprecise curing around the edges of the 3D product. Blurring throughout the photopolymerization process will result in deformation and incomplete curing at the outer edges of the projected area, causing a lack of solid edges in the projected area. In some embodiments, the method further includes intentionally focusing and defocusing the projector throughout the additive manufacturing process. In some embodiments, the method further includes using an additional radiation source. In some embodiments, the additional radiation source further comprises a laser. In some embodiments, the projector further comprises a collimating lens. In some embodiments, multiple collimating lenses are used at different heights. In some embodiments, the projector array utilizes one or more collimating lenses such that the entire projected area of ​​the array is collimated by one or more collimating lenses. In some embodiments, the projector having a collimating lens is positioned further from the interface than the projector without a collimating lens. The collimating lens generates perfectly perpendicular pixel lines, which effectively eliminates stress zones caused by the outward angle of radiation from the projector. In some embodiments, the collimating lens moves laterally throughout the additive manufacturing process.

[0154] However, perfectly perpendicular pixel lines are also not ideal, as they generate numerous thin perpendicular stress bands. An additional method of intentional defocusing is the use of a light scattering agent at the interface between the radiation source and the resin. Any tank polymerization process requires a certain material at the interface with the polymerizable resin. In some embodiments, a suitable 3D printing interface further comprises a light scattering agent. The light scattering agent at the interface will induce randomness in the radiation as it reaches the polymerizable resin. This defocuses the radiation at the interface, which can allow for the elimination of defects caused by pixel overlap and inter-pixel gaps. Suitable light scattering agents include titanium dioxide. Manipulating the type of scattering that occurs involves modifying the refractive index of the interface material and the size and shape of the selected scattering agent. In some embodiments, the scattering agent is selected to have a high refractive index. In some embodiments, the refractive index of a suitable scattering agent is greater than 2, more preferably greater than 2.25, more preferably greater than 2.5, and more preferably greater than 2.75. In some embodiments, the interface material is selected to match the refractive index of the resin formulation, which will ensure consistent scattering throughout the tank. In one embodiment, the interface material is selected to have maximum light transmittance, which will allow for control of the maximum level of light scattering. Elastic light scattering occurs when the scattered rays of light have the same wavelength as the incident rays. For a given light scattering agent, the angle of elastic scattering is inversely proportional to the particle size. For a given light scattering agent, the total amount of scattered light is directly proportional to the particle size. These two factors determine the type of elastic scattering that will occur. Light scattering particles are categorized by a dimensionless size parameter, which is calculated using the following formula.

number

[0155] In some embodiments, scattering is achieved by dispersing particles of a light scattering agent throughout the interface. In some embodiments, the particle size parameter is greater than 0.1, more preferably greater than 0.5, more preferably greater than 1, and more preferably greater than 2. In some embodiments, a combination of Mie and Raleigh scattering is used. In some embodiments, the interface layer is refractive index matched to the resin formulation. As the optical components are pulled away from the liquid interface, the interface is pulled up slightly along with the components. This can create a “lens” within the interface because the high refractive index resin refracts light to a much greater extent than a non-refractive index matched resin, which in turn will refract most of the light intensity outward away from the center of the optical components. Refractive index matching the interface to the resin ensures that there is no change in IR as radiation passes from the interface into the resin. The software reads the SDF file format, converts it directly into an image stack, and imports it into the software.

[0156] In some embodiments, pixel intensity and / or shape pre-distortion may occur with respect to the image stack or as each image is created. CAD-free printing of optical lenses is also possible, according to the present invention, using a dot array.

[0157] Dot arrays are used to provide the shape of a lens during conventional manufacturing, and their 3D structures are saved as Signed Distance Field (.sdf) files. In one embodiment, the present invention provides a medium that makes it possible to additively manufacture a lens directly from an .sdf file. Such a medium may convert the .sdf file into an image stack by associating each layer of dots with a shape, and emit patterned radiation into the resin based on that shape.

[0158] In some embodiments, sequentially emitting patterned energy further includes emitting energy having a fluctuating intensity. In some embodiments, generating an image stack further includes determining the radiant intensity that each pixel of the image in the image stack will receive. A technique commonly referred to as "grayscaling" is known to additive manufacturers. Grayscaling refers to the fluctuating intensity of energy emitted from a radiation source so that some voxel resins are administered with a greater intensity than others. In conventional additive manufacturing techniques, grayscaling can increase the precision capabilities of the printer and ensure that each voxel of the resin receives a precise amount of energy desired to form the desired shape and undergo the desired amount of polymerization. Grayscaling techniques can further enable sub-pixel resolution and thus allow for greater control over all aspects of the 3D printed part. Continuous vat polymerization techniques can enjoy further benefits from grayscaling. The degree of polymerization of a given voxel of resin is directly proportional to the total amount of energy received by the voxel. Through the use of grayscaling, energy of varying intensity can be released into different voxels over a given time period, and thus different voxels receive different total amounts of energy and achieve different degrees of polymerization. Different types of polymerization can be achieved during the printing process compared to post-printing treatments (i.e., chain extension vs. crosslinking), and therefore grayscaling can be used to modify the homogeneous polymer network of an article produced using sustained vat polymerization. Grayscaling can also be used to mitigate roughness caused by blurring. Preferred non-limiting embodiments of grayscaling techniques include algorithmic grayscaling, dithering grayscaling, or white noise grayscaling.

[0159] In one embodiment, the radiation source is located within the resin tank outside the pre-gelling zone. In one embodiment, the radiation source is a suppression radiation source. The suppression radiation source will facilitate the removal of excess resin adhering to the surface of the unmolded product. In one embodiment, the radiation source can move throughout the resin tank during polymerization. In one embodiment, the radiation source is located within the construction surface. In one embodiment, the suppression radiation source emits radiation at different wavelengths of light than the polymerization radiation source. In one embodiment, the suppression radiation source is located on the construction surface. This embodiment allows the suppression radiation to be directly reflected within the part. In one embodiment, the resin tank further comprises an upper liquid layer. In one embodiment, the upper liquid layer is immiscible with the resin formulation. In one embodiment, the liquid layer is

[0160] Pre-gelation zone device In accordance with the embodiments described herein, a truly continuous additive manufacturing ("AM") machine may be required to maintain the pre-gelled zone. Continuous AM, i.e., constant pull throughout, may require some reduction in the adhesive force acting on the parts. Preferred techniques may include HARP, CLIP, and any other tank polymerization printing process. HARP operates through a mobile liquid interface that generates shear stress directly beneath the appearing part, creating a slip boundary (see https: / / www.sclence.org / doi / 10.1126 / science.aax / 562).

[0161] The slip boundary allows the solidified part to be continuously retracted from the printing interface. Fluorinated oils (perfluoropolyether copolymers such as Fomblin Y from Solvay or Krytox GPL from Chemours) may be used due to their omnidirectional repulsive properties and higher density compared to those of general SLA resins. CLIP oxygenates the area above the interface, preventing curing (dead zone). Therefore, the pre-gelling zone for such a CLIP system does not start at the interface, but instead starts directly above the dead zone where polymerization begins. In such a system, the pre-gelling zone thickness is the distance in the Z direction between the point where curing begins and the gel point boundary. Post-printing treatment of optical lens components involves further curing of the optical components outside the printer. Additional post-printing steps may be performed to ensure the production of quality optical components, add customizable features, and modify the properties of the optical components. In some embodiments, post-printing treatment of optical lenses includes a cleaning step, a spinning step, a coating step, a polishing step, a spraying step, a UV curing step, a heat curing step, and combinations thereof. In some embodiments, the optical components are provided with a support structure capable of supporting the optical components throughout at least one of these post-printing steps. In some embodiments, a sustained-tank polymerization 3D printer provides a construction surface on which optical components are polymerized. In some embodiments, the construction surface is a removable construction surface capable of supporting the optical components throughout at least one post-printing step. In some embodiments, the support structure includes an adhesive zone intended for attaching the optical components to the removable construction surface.

[0162] All additively manufactured parts must undergo a cleaning step. This cleaning step ensures that all uncured resin present on the surface of the 3D printed part is removed. This cleaning step should be performed prior to any further curing to ensure that only the desired amount of solidified resin is present in the final product. In some embodiments, the cleaning step further includes immersing the unmolded product in a liquid that, based on the resin formulation, allows for the removal of excess resin from the part. A typical cleaning step utilizes 90-100% isopropyl alcohol (IPA), which is suitable for removing most of the uncured resin.

[0163] In addition to the washing step, a spin step may be performed for further removal of additive resin. In some embodiments, the spin step involves rotating the unmolded product at a speed that allows for the removal of excess uncured resin from the unmolded product. The spin step may be performed instead of or in addition to the washing step to ensure the removal of excess resin. Optionally, a heated air blade may be used in addition to or as an alternative to spinning. In some embodiments, the heated air blade is used while the unmolded product is still in the additive manufacturing apparatus to remove excess resin from the polymerized portion of the unmolded product.

[0164] Once excess resin is removed, further processing of the optical component may occur. In some embodiments, once excess resin is removed, a coating step is performed. The coating step involves placing a thin film on the surface of the component, which can provide beneficial properties and remove minor imperfections within the surface of the component. In some embodiments, the coating step includes coating the optical component with a refractive index matching material. This refractive index matching material fills any microscopic imperfections and, since its refractive index is identical to that of the optical lens precursor, will not alter the optical properties of the optical component. In some embodiments, the refractive index matching material is a resin formulation used to print the optical component, with added viscosity increasers to ensure the component is adequately coated. In some embodiments, the refractive index matching material further provides abrasion resistance, anti-reflective properties, absorbent properties, polarizing properties, or a combination thereof. Most lenses produced using any manufacturing method undergo coating treatment to impart beneficial properties to the lens. Preferred coating techniques include, but are not limited to, immersion coating, spin coating, or vapor coating. In some embodiments, a coating step for an optical component comprising an optical lens precursor includes applying the coating only to the optical lens precursor. In some embodiments, the coating step includes applying the coating to the entire optical component, including the optical lens precursor and any other components. In some embodiments, the coating step further includes a hard coating step. In some embodiments, the hard coating step includes specifically applying an abrasion-resistant coating to the optical component using any preferred coating technique. In some embodiments, both the optical lens precursor and the frame undergo the hard coating step.

[0165] In some embodiments, once excess resin has been removed, a polishing step is performed. For general additive manufacturing purposes, the polishing step is performed to ensure a smooth surface of the part to be 3D printed. This typically takes the form of sanding the part before or after the coating is applied. For optical lens manufacturing, polishing provides an important step to ensure optical clarity. In addition, polishing of optical components, including optical lens precursors, can further ensure that the geometric shape and curvature of the lens are formed, that it fits into a frame, and that it has appropriate field-correcting properties. Optical components may undergo a polishing step prior to or after the coating step. In some embodiments, the polishing step is a chemical-mechanical polishing step, which utilizes mechanical polishing and a chemical slurry, making it possible to effectively remove imperfections and ensure that the dimensions of the optical component are maintained.

[0166] Further curing of unmolded products outside the printer is a crucial element of post-printing treatment of unmolded products. The resin solidified within the unmolded product polymerizes to a point where it can retain a solid structure. However, the unmolded product does not achieve 100% polymerization throughout. In most cases, this is done intentionally to allow further type of curing to occur outside the printer, which can induce certain mechanical properties within the part. In some embodiments, post-printing curing further comprises further UV curing. In some embodiments, UV curing involves exposing the unmolded product to a UV lamp. This curing promotes further polymerization of the unmolded product on the surface of the part. In some embodiments, post-printing curing further comprises thermal curing. In some embodiments, thermal curing occurs at a temperature higher than the temperature at which the thermal initiator decomposes and initiates polymerization, but lower than the thermal deflection temperature of the optical component. In some embodiments, post-printing curing further comprises a combination of UV and thermal curing. In some embodiments, the combination of UV and thermal curing involves using a combination of UV and thermal curing to induce a desired crosslinking and chain extension ratio within the final product. In some embodiments, thermosetting is used to increase the disorder of the polymer network when silicon groups are present in the resin formulation. In some embodiments, the thermosetting step increases the energy of the polymer network, disrupting non-covalent thiol-thiol interactions and causing thiols to interact with aromatic rings. The additional thermal energy alters the free energy of the network, allowing for the achievement of greater disorder than in the absence of thermosetting.

[0167] In some embodiments, the post-printing treatment further includes a spraying step. In some embodiments, this spraying step can apply a surface coating to an optical component. This spraying step is particularly useful when the optical component includes a frame. The spraying step can apply a color coating to the frame while maintaining the optical clarity of the optical lens or optical lens precursor.

[0168] In some embodiments, the post-printing process further includes a double surface finishing polishing step. In some embodiments, the double surface finishing polishing step further includes fixing the optical component through its edges so that the first and second surfaces of the optical component are accessible. In some embodiments, the double surface finishing polishing step further includes polishing the optical component simultaneously on two surfaces, for example, using a CNC machine. In some embodiments, the double surface polishing includes matching random patterns on both surfaces such that the force applied by the polishing device applies equal force to the same locations on both surfaces of the optical component simultaneously. This would facilitate the maintenance of the geometric shape of the optical component throughout the polishing process, as there is a significant likelihood that the force from the polishing device on one surface of the optical component will cause physical deformation of the optical component if it does not accompany an equal force at the corresponding location on the second surface.

[0169] Post-printing processing steps can occur in various orders. In some embodiments, an excess resin removal step is performed first. In some embodiments, the excess resin removal step is a washing step, a spinning step, or a combination thereof. In some embodiments, post-printing curing occurs, immediately followed by the resin removal step. In some embodiments, post-printing curing comprises UV curing, thermal curing, or a combination thereof. In some embodiments, a polishing step follows the post-printing curing step. In some embodiments, a coating step follows the post-printing curing step. In some embodiments, a spraying step follows the post-printing curing step. In some embodiments, a polishing step, spraying step, coating step, or a combination thereof occurs after the excess resin removal step, but prior to the post-printing curing step. In some embodiments, multiple coating steps are performed. In some embodiments, the lens is coated with a refractive index matching material to remove any imperfections in the optical lens precursor, and then a second hard coating step is performed to give the optical component wear resistance and / or anti-reflective properties. In some embodiments, an optical lens is printed to have a microstructure on at least one surface of the lens. A preferred microstructure may comprise a series of ridges and / or deformations having a depth of 0.50 to 6.00 microns inside and outside at least one surface of the lens. A preferred microstructure may comprise a series of ridges and / or deformations spaced at least about 36.0 microns apart. In some embodiments, a first coating step is performed prior to post-curing, and a hard coating step is performed after the post-curing step. In some embodiments, the hard coating step is performed after the polishing step. In some embodiments, the optical component having the microstructure is coated such that a smooth surface is achieved after the completion of the coating step. In some embodiments, a spin coating method is used. In some embodiments, a dip coating method is used. This will ensure that the lens is perfectly smooth prior to the hard coating step. This allows the use of a hard coating material that is refractive mismatched.This has the further benefit of allowing the optical components, comprising an optical lens precursor and a frame, to be completely coated with an abrasion-resistant coating, which will increase the abrasion resistance of both the frame and the lens in the final product.

[0170] In some embodiments, the coating step further includes an additional UV curing step. Structural and chemical advantages are available when the additively manufactured product has not achieved 100% curing prior to the additional post-treatment step. If the product is not fully cured, reactive parts still exist in and on the surface of the product. Functional groups may be covalently bonded to these reactive parts, which can provide additional functional and manufacturing benefits. In some embodiments, the coating step, including an additional UV curing step, allows the hard coating to covalently bond to the exposed reactive groups of the unformed product. In some embodiments, an interface region exists within the final product between the additively manufactured lens and the hard coating. In some embodiments, the hard coating generates stronger adhesion between the hard coating and the lens in the presence of UV curing than the coating in the absence of UV curing. In some embodiments, this forms a unique lens. In some embodiments, the present invention provides an additively manufactured lens comprising a body layer, a coating layer, and an interface region, the interface region comprising sides of the body layer and the coating layer that are covalently bonded to each other. In some aspects, the coating layer is a hard coating. In one respect, the coating layer is an anti-reflective coating. In another respect, the coating layer is a blue light-absorbing coating.

[0171] Combinations of step components will also be considered within the scope of the invention, in particular, even if the ability to separate or combine them is unclear or predictable. The disjunctive term “or” is generally intended to mean “and / or” unless otherwise indicated, as used herein and throughout the following claims, and has both conjunctive and disjunctive meanings (but not limited to the meaning of “exclusive or”). As used herein and throughout the following claims, “a,” “an,” and “the” include plural references unless otherwise clearly determined by the context. Also, as used herein and throughout the following claims, the meaning of “in” includes “in” and “on” unless otherwise clearly determined by the context.

[0172] Figure 1 shows an illustrative continuous tank polymerization printer 100. The printer 100 may include a resin tank 102. The resin may be contained in the tank or may flow in and out of the tank. The printer 100 may include a projector 104. Alternatively, the projector 104 may be a liquid crystal display, laser, or scanning laser projector. The printer 100 may include an interface 106, which may be a radiation-permeable liquid, gel, membrane, film, or solid material. The interface may be either steady or mobile during the printing process. For example, the interface may be a fluorinated oil (e.g., a perfluoropolyether copolymer such as Fomblin Y from Solvay or Krytox GPL from Chemours). The projector 104 may emit radiation 108. The radiation 108 may permeate through the interface 106. Radiation can be in the form of heat, magnetic radiation, or light (including UV, visible, or infrared light, each of which may have a specific wavelength or a broad band of wavelengths). When radiation 108 comes into contact with the resin 110 in the resin tank 102, the resin 110 may begin to harden. The printer 100 may include a construction platform 112. The construction platform 112 may be positioned near the interface 106. The construction platform 112 may be moved in the Z- or -Z direction. The construction platform may be moved in one or more of the X, -X, Y, and -Y directions. The construction platform 112 may be rotated.

[0173] When the construction platform 112 is positioned adjacent to the interface 106, the resin 110, which is activated by radiation 108, may adhere to the construction platform 112. The construction platform 112 may be pulled in the Z direction with the activated resin 110 attached to it. As the construction platform 112 is pulled in the Z direction, additional resin 110 may be activated and adhere to the resin 110 already attached to the construction platform 112.

[0174] The resin 110, which is attached to the construction platform 112, may contain monomers, oligomers, and polymers that are weakly bonded to each other. As the monomers, oligomers, and polymers are pulled by the construction platform 112, they continue to receive energy from the radiation 108. This energy continues to bond the monomers, oligomers, and polymers to each other.

[0175] The resin 110, which is attached to the construction platform 112, may form a body B. The body B may have a linear proximal boundary ("P") with respect to the interface 106. The body B may have a linear distal boundary ("D") with respect to the interface 106. The body B may have a curved proximal boundary ("P") with respect to the interface 106. The body B may have a nonlinear distal boundary ("D") with respect to the interface 106. The body B may have a non-uniform proximal boundary ("P") with respect to the interface 106. P is the location where polymerization of the resin begins to occur in the Z direction. In the embodiment of Figure 1, the upper part of the interface is the location where such polymerization of the resin begins to occur, and is therefore P in that embodiment.

[0176] Body B may include a pre-gelling zone. In the pre-gelling zone, the resin body B is insufficiently cured and considered a gel. Above the gel point boundary GP, body B becomes a gel body. The gel body is a material that is sufficiently cured to maintain its structure but continues to cure during the printing process. In the hardening zone HZ, the gel body continues to cure under the influence of radiation 10⁸. Materials with higher Z values ​​may be exposed to radiation 10⁸ for longer and therefore may be more cured than materials with lower Z values. The degree of curing may increase with increasing Z through the hardening zone HZ. Radiation may be non-uniform both in XY and as a function of time. The degree of curing with respect to a given Z may differ in different snapshots of time during printing.

[0177] At the edge of the hardening zone HZ distal to the interface, the gel body can achieve a rigidity that cannot be present in the more proximal region of the gel body. At the edge of the hardening zone HZ, the body reaches a degree of hardening that can be considered final curing ("FCOP") on the printer. Above FCOP, little to no further hardening can occur from the projector 104. FCOP may be above or below the surface 114 of the resin 110. FCOP may be less than 100% completely cured. For example, FCOP may be 70-90% completely cured. Complete curing may be performed outside the printer. Sometimes FCOP is an equal percentage, sometimes it is a range, and sometimes FCOP is determined by the geometry of the body at each Z position.

[0178] When the construction platform 112 is pulled in direction Z, a reactive force F may be generated. Force F may arise from the adhesive force between the resin in the pre-gelling zone and the interface 106. Force F is calculated as (resulting from the Stefan adhesive force arising from the resin viscosity (α)) × (body radius). 4 × (1 / (body height (Z))) 3 It can be proportional to ). The pre-gelation zone is the thickness between interface 106 and gel point GP.

[0179] The size of the pre-gelation zone may be controlled to enhance the properties of the main body B. The pre-gelation zone thickness PGZT is the distance from boundary P to boundary GP.

[0180] Figure 2 shows the printer 100 that constructs the main body B1. In the main body B1, the pre-gelling zone thickness may vary across the width of the main body B1. For example, the pre-gelling zone thickness may be a function PGZT(x,y). The pre-gelling zone may have a non-linear proximal boundary. The pre-gelling zone may have a non-linear distal boundary. The hardening zone HZ may have a corresponding curvature. The hardening zone HZ may have a linear proximal boundary.

[0181] Figure 3 shows a collimator 302, which may be contained within the printer 100. The collimator 302 may include a collimating lens, a focusing lens, or a series of lenses. The projector 104 may have an adjustable element configured to adjust the position of the focal plane 304. The focal plane 304 is illustrated to be positioned at position Z1. The focal plane 304 may be aligned with the incident end of the collimator 302. The collimator 302 may receive divergent pixels of radiation 108. The collimator 302 may split the radiation 108 into divergent pixels. The collimator 302 may collimate the pixels. Each pixel may emerge from the collimator 302 with an intensity distribution such as 306. Gaps such as 308 may exist between pixels. The gap 308 can be defined as an area having an intensity that is at least 30% lower than the center of the pixel. The gap 308 extends in the Z direction within the main body B and can cause optical aberrations.

[0182] Figure 4 shows the focal plane 304 positioned at position Z2. The focal plane 304 may be offset from the incident end of the collimator 302. When the focal plane 304 is positioned at Z1, the collimator 302 may receive divergent pixels of radiation 108 in a less focused state. Each pixel may emerge from the collimator 302 with an intensity distribution such as 406, which diverges from distribution 306. Distributions 406 may overlap, thus eliminating gaps 308. Overlap can reduce or avoid optical aberrations within the body B. The focal plane 304 may move from Z1 to Z2 and back during the printing process. The focal plane 304 may move above Z1 and then back below one or both Z1 and Z2.

[0183] Figure 5 shows an XY positioner 502, which may be contained within the printer 100. Pixels emerging from the collimator 302 may appear at an angle α relative to the collimator 302. Angle α may be 90°. The XY positioner 502 can shift the collimator 302 in the plane XY. The collimator 302 is illustrated as being at position X1.

[0184] The XY positioner 502 may instead be attached to the projector 104. This would produce an effect similar to that shown in Figure 6. The XY positioner 502 may also be attached to both the projector 104 and the collimator 302, and they may be moved in conjunction with each other.

[0185] Figure 6 shows the collimator 302 being displaced from position X1 to position X2. When the collimator 302 is displaced from the projector 104, the angle α can be displaced to an angle less than 90°. By displacing the collimator 302, the appearing pixels can be swept across a region that would otherwise be affected by gaps such as 308.

[0186] Figure 7 shows the spatial distribution of radiation intensity corresponding to intensity distribution 306.

[0187] Figure 8 shows the spatial distribution of radiation intensity corresponding to intensity distribution 406. This spatial distribution may also correspond to the time-averaged intensity distribution resulting from the shift at angle α.

[0188] Figure 9 shows an illustrative printer 900. Printer 900 may have one or more features common to printer 100. Printer 900 may include a resin tank 902. Printer 900 may contain resin 910. Printer 900 may include a construction platform 912. Printer 900 may include a projector 904. The projector 904 may extend further in the X or Y direction than the main body B2.

[0189] The printer 900 may be configured to move the construction platform 912 along a trajectory S(t). The trajectory S(t) may have a Z component. The trajectory S(t) may have an X component. The trajectory S(t) may have a Y component. The trajectory S(t) moves in both positive and / or negative directions and may be at the same (X,Y) coordinates more than once. By moving the construction platform 912 along the trajectory S, the appearing pixels may be swept across an area that would otherwise be affected by gaps such as 308. With respect to a larger body B2, the body B2 may have a trajectory S(t) that moves across a plurality of projectors 904 that are tiled together. The trajectory S(t) of the construction platform 912 is relative to radiation, which proceeds through the interface into the resin. This means that the construction platform 912 may not be moving in the XY plane relative to the interface 906 and the resin tank 902. In this case, the radiation would be moving in the XY direction relative to the interface 906 and the resin tank 902.

[0190] Arrow A represents one or more axes of rotation on the construction platform 912. Printer 100 or 900 may rotate the construction platform in one or more of the ZX plane, ZY plane, XY plane, or an arbitrary oblique plane. The rotation may depend on time, position along S, or both.

[0191] Figure 10 shows an illustrative body B3 that may be printed by a printer such as a 100 or 900. Body B3 may have one or more features common to one or both of body B, body B1, and body B2. Body B3 may include a support 1002. Body B3 may include a lens 1004. The support 1002 may be monolithic with the lens 1004. Body B3 may be cured on the printer to FCOP. The support 1002 may be engaged with the target lens 1004 by a robot for post-print handling. The support 802 may be bonded to the construction platform 112 so that all three can be engaged during post-print handling.

[0192] Figure 11 shows the main body B3 from an orthogonal angle centered on the center line CL, relative to the previous figure of the main body B3. The lens 1004 may include a surface S1. The lens 1004 may include a surface S2. The printer may print the main body B3 based on a file containing distance data for one or both of S1 and S2. The data may define a distance function Ds1(Z,Y) for surface S1. The data may define a distance function Ds2(Z,Y) for surface S2. Distance data for the support 1002 may be included in the file. The support 1002 may be tapered to minimize material or to maximize stability. Ideally, the support matches the dimensions of the lens 1004 at the surfaces where they join. The support 1002 may be an extension of the lens geometric shape with a surface having an XY profile for matching and bonding to the construction platform 112.

[0193] Figure 12 shows an illustrative body B4 that can be printed by a printer such as a 100 or 900. Body B4 may have one or more features common to one or more of body B, body B1, body B2, and body B3. Body B4 may include a support 1202. Body B4 may include a lens 1204. The support 1202 may be monolithic with the lens 1204. Body B4 may be cured on the printer to FCOP. The support 1202 may be engaged with the target lens 1204 by a robot for post-printing handling. The support 1204 may be continuous with the periphery 1206 of the lens 1204. Body B4 may therefore be seated in a frame for single-sided chemical deposition of the lens coating material. The support 1204 may support body B4 in a manner in which one side of the lens 1204 faces the chemical vapor atmosphere. The support 1204 can prevent chemical vapors from advancing to the other side of the lens 1204. The lens 1204 may have a range, shape, and size that utilizes the same outer dimensions as 1202.

[0194] Figure 13 shows the main body B4 from an orthogonal angle centered on the center line CL, relative to the previous figure of the main body B4. The lens 1204 may include a surface S3. The lens 1204 may include a surface S4. The printer may print the main body B4 based on a file containing distance data for one or both of S1 and S2. The data may define a distance function Ds3(Z,Y) for surface S3. The data may define a distance function Ds4(Z,Y) for surface S4. Distance data for the support 1202 may be included in the file. The support 1202 may be tapered, i.e., have a thickness change for a more gradual or even more seamless transition from the support to the lens 1204.

[0195] The apparatus may omit features illustrated and / or described in relation to the illustrative apparatus. Embodiments may include features not illustrated or described in relation to the illustrative apparatus. Features of the illustrative apparatus may be combined. For example, an illustrative embodiment may include features shown in relation to another illustrative embodiment.

[0196] For illustrative purposes, the illustrated steps of the process will be described as being performed by the “System.” The “System” may include one or more features of the apparatus and schemes and / or any other suitable devices or approaches illustrated or described herein. The “System” may include one or more means for performing one or more steps described herein.

[0197] The steps of the method may be carried out in an order other than that illustrated and / or described herein. Embodiments may omit steps illustrated and / or described in relation to the illustrative method. Embodiments may include steps that are not illustrated or described in relation to the illustrative method.

[0198] The illustrative method steps may be combined. For example, an illustrative process may include steps that are shown in relation to another illustrative process.

[0199] Figure 14 illustrates the illustrative steps of process 1400 for constructing the body using a controlled pre-gelling zone thickness such as PGZT(x,y). The process may start from step 1402. In step 1402, the system may receive shape data. The shape data may be entered into the system by the user. The shape data may be contained in an SDF file.

[0200] In step 1404, the system may receive a set of parameters to control (e.g., pre-gelling zone thickness or force F) and control values ​​for the parameters (e.g., 300 microns for thickness or a desired number of Newtons for F). In step 1406, the system may receive resin dynamic parameters. The parameters may include activation energy. The parameters may include penetration depth.

[0201] In step 1408, the system may output process parameters. These process parameters may include the displacement rate to which the construction platform should be moved. The process parameters may also include light intensity. Light intensity may be expressed as a percentage of the maximum light intensity. Light intensity may be expressed as refractive force / unit area. Light intensity may correspond to the light intensity incident on the interface.

[0202] In step 1410, the system may receive feedback. The feedback may include the pre-gelling zone thickness. The feedback may include a force F. The feedback may include light intensity. The feedback may include attraction coefficient. The feedback may include resin temperature. The feedback may include resin curing degree. The curing degree may be based on optical transmittance. The curing degree may be based on scanning calorimetry. The feedback may be generated by telemetry. The feedback may be obtained by user observation.

[0203] Figure 15 illustrates the illustrative steps of process 1500 for constructing the main body with aberration mitigation. In step 1502, the system may receive an SDF file defining a first lens surface. In step 1504, the system may receive data defining a second lens surface. The second lens surface may be defined in a separate SDF file. The second lens surface may be defined in the same SDF file in which the first lens surface is defined.

[0204] In step 1506, the system may identify N XY slices through a body to be constructed based on the first and second lens surface data.

[0205] In step 1508, the system may assign a radiation intensity command to each pixel within each slice. The radiation intensity command may also be assigned per slice.

[0206] In step 1510, the system may assign aberration mitigation commands to each pixel or slice within each slide. The aberration mitigation commands may correspond to changes in the projector's focal length. The aberration mitigation commands may correspond to changes in the incident angle of pixels on the interface. The aberration mitigation commands may include a trajectory (e.g., S) or trajectory velocity (e.g., dS / dt).

[0207] In step 1512, the system may, based on radiation intensity commands and aberration mitigation commands, instruct the projector to move the construction platform for each slice of the main body and project the radiation (starting from a location adjacent to the construction platform).

[0208] In step 1514, the system may receive feedback. The feedback may include the pre-gelling zone thickness. The feedback may include a force F. The feedback may include light intensity. The feedback may include attraction coefficient. The feedback may include resin temperature. The feedback may include resin curing degree. The curing degree may be based on optical transmittance. The curing degree may be based on scanning calorimetry. The feedback may be based on optical scattering in response to variations in curing degree within the body. The feedback may be generated by telemetry. The feedback may be obtained by user observation.

[0209] Figure 16 illustrates the interface layer 1610, within which stress zones may occur due to the collimating lens 1600.

[0210] In 1613, a window is shown to allow projection of radiation through it. An interfacial bubble is shown in 1614. Such a bubble 1614, which may be formed as a result of the application of force to a cured or semi-cured part, acts like a lens, causing non-uniform curing of the part within the resin layer 1620.

[0211] Figure 17 illustrates the collimating lens 1700, the interface layer 1710, the window 1713, and the resin layer 1720. Figure 17 also shows the scattered particles 1712 in the resin.

[0212] Figure 17 illustrates the use of a collimating lens 1700 in combination with scattering particles 1712 at the interface. Such a combination preferably results in uniform curing with no or substantially no stress bands within the cured lens. The embodiment shown in Figure 17 is further another example of a method for mitigating aberrations within a cured lens.

[0213] Figure 18 shows yet another approach to mitigate aberrations. Specifically, Figure 18 shows pixel blurring by overlapping the projection areas of multiple projectors 1800.

[0214] In 1801, a single projector is shown. In 1802, the area of ​​radiation is shown. In 1804, an exploded view of the area shown in 1802 is shown. Note that in the various areas of radiation in exploded view 1804, stress regions may arise because the pixels are hardened individually in an unblurred manner. Such unblurred hardening can cause areas of relatively low-intensity radiation between areas of high-intensity radiation. Such low-intensity areas can cause non-uniform hardening and, potentially, stress zones.

[0215] In 1800, pixel blurring using the overlapping projection areas of multiple projectors 1800 is shown. Specifically, 1803 shows a hardened region. In 1806, an exploded view of the region shown in 1803 is shown. Note that in the various regions 1806 of the exploded view 1803, stress regions are eliminated because the pixels are hardened in a blurred manner due to multiple projectors 1800. Such blurred pixels can acquire hardening without stress zones.

[0216] Figure 19 shows a physical mask for placement across a projector, as described herein. The physical mask may be used to shape the periphery of the cross-section of the main body.

[0217] In 1900, a curved projector mask is shown. In 1910, the mask base is shown. In 1920, two opposing surfaces of a linear actuator are shown. In 1930, a flexible bladder is shown.

[0218] Figure 20 shows a precise method for constructing the cross-section of the main body (see, for example, printer 900 in Figure 9 above).

[0219] In 2010, the interface is shown. In 2020, the resin layer is shown. The adhesive step 2002 is shown. In 2030, an optical component having a curved surface is shown. In 2040, the adhesive step is shown. Therefore, Figure 20 shows the curved direction of movement, and the normal of the curved surface of the optical component 2030, such as a lens, remains perpendicular or approximately perpendicular to the interface 2010. In 2000, the radiation source, including its projected area, is shown.

[0220] Figure 21 shows selective inhibition of curing using multiple radiation sources. Figure 21 illustrates multiple curing radiation sources 2100. 2141 shows the interface 2110. 2120 shows the resin layer. 2140 shows the bonding layer. 2102 shows multiple radiation sources. Radiation source 2102 may be used to selectively inhibit curing.

[0221] Figure 22 shows a cross-sectional view of an embodiment of the optical lens 2210. The optical lens 2210 preferably includes an optical lens body layer 2211, an optical lens coating layer 2212, and an interface region 2213. The interface region 2213 is located between the optical lens body layer 2211 and the optical lens coating layer 2212.

[0222] Figure 23 shows a top plan view of the optical lens support structure. The optical lens support structure exhibits a multi-construction platform design, where each construction platform has an identifier relating to the associated optical lens component. Specifically, Figure 23 shows barcode 2341 placed on the optical lens support structure.

[0223] Such a support structure may include a projection portion 2340 on which a barcode may be etched, embossed, or otherwise indicated. The projection portion 2340 may extend from a structural spine 2345. Such a barcode 2341 may be used in conjunction with a robotic wet coating. Such a wet coating may be implemented by dipping.

[0224] Figure 24 shows a side view of the optical lens support structure shown in Figure 23. Specifically, Figure 24 shows a side view of the projection section 2440 and the spine 2445. In addition, Figure 24 shows the square structure in 2430 and the adhesive step embodiment in 2432. Furthermore, Figure 24 shows a plurality of optical lenses 2400.

[0225] Figure 25 shows a perspective view of the optical component 2500. The optical component includes a support structure 2530. In addition to the optical component 2500 shown in Figure 25, a vapor coating apparatus is also shown in 2550.

[0226] The optical component 2500 further includes an optical lens precursor 2520, a first surface 2521, and a peripheral portion 2523. In 2531, a square embodiment of the support structure is shown.

[0227] Figure 26 shows a plan view of the optical components from Figure 25.

[0228] The optical component 2600 includes a support structure 2630.

[0229] The optical component 2600 further includes an optical lens precursor 2620, a first surface 2621, and a peripheral portion 2623.

[0230] In 2631, a square embodiment of the support structure is shown. The square embodiment is shown to have an exemplary length and width of 85 millimeters ("mm"), but other preferred lengths and / or widths, such as 65 mm, are also within the disclosure of this application.

[0231] Figure 27 shows a plan view of the embodiment from Figure 26. However, Figure 27 also shows an additional embodiment of the optical component 2700. Note that the support structure 2630 shown in Figure 6 is the same size as the support structure 2730 shown in Figure 27, i.e., 85 mm, but the optical component 2600 shown in Figure 26 has a different size from the optical precursor 2700 shown in Figure 27.

[0232] Figure 28 shows a perspective view of an alternative embodiment of the optical component 2800. The optical component 2800 includes a support structure 2830.

[0233] The support structure 2830 includes an adhesive step 2840 for attachment to the spin coating apparatus 2802. The optical component 2800 further includes an optical lens precursor 2820, a first surface 2821, a second surface 2822, and a peripheral portion 2823. An embodiment 2832 of the adhesive step of the support structure 2830 is also shown.

[0234] FIG. 29 shows a perspective view of an alternative embodiment of an optical component 2900. The optical component 2900 includes an adhesive step embodiment 2932 of a support structure 2930 and a vapor coating structure 2902. The optical component 2900 further preferably includes an optical lens precursor 2920, a first surface 2921, and a peripheral portion 2923 such that an airtight seal (shown schematically) is formed at the peripheral portion of the optical component 2900.

[0235] FIG. 30 is a block diagram illustrating a computing server 3001 (alternatively, referred to herein as a "server or computer") that may be used in accordance with the principles of the present invention. The server 3001 may have a processor 3003 to control the overall operation of the server and its associated components, including a server, RAM 3005, ROM 3007, an input / output ("I / O") module 3009, and a memory 3015.

[0236] The I / O module 3009 may include a microphone, a keypad, a touch screen, and / or a stylus through which a user of the server 3001 may provide input, and may also include one or more than one of a speaker for providing audio output and a video display device for providing text, visual, and / or graphical output. Software may be stored in the memory 3015 and / or other storage devices (not shown) and may provide instructions to the processor 3003 to enable the server 3001 to perform various functions. For example, the memory 3015 may store software used by the server 3001, such as an operating system 3017, an application program 3019, and an associated database 3011. Alternatively, some or all of the computer-executable instructions of the server 3001 may be embodied in hardware or firmware (not shown).

[0237] Server 3001 may operate in a networked environment that supports connections to one or more remote computers, such as terminals 3041 and 3051. Terminals 3041 and 3051 may be personal computers or servers that include many or all of the elements described above with respect to Server 3001. The network connections depicted in Figure 30 include, but may also include, a local area network (LAN) 3025 and a wide area network (WAN) 3029.

[0238] When used in a LAN networking environment, server 3001 is connected to LAN 3025 via a network interface or adapter 3013.

[0239] When used in a WAN networking environment, the server 3001 may include a modem 3027 or other means to establish communication via the WAN 3029, such as the Internet 3031.

[0240] The network connection described is illustrative, and it should be understood that other means of establishing communication links between computers may be used. The existence of any of the various well-known protocols, such as TCP / IP, Ethernet®, FTP, HTTP, and equivalents, is assumed, and the system operates in a client-server configuration, allowing users to access web pages from a web-based server. Any of the various conventional web browsers may be used to view and manipulate data on web pages.

[0241] In addition, the application program 3019, which may be used by the server 3001, may include computer executable instructions for invoking user functionalities related to communication, such as email, short message service (SMS), and voice input and speech recognition applications.

[0242] The computing server 3001 and / or terminal 3041 or 3051 may also be a mobile terminal, including various other components such as a battery, speaker, and antenna (not shown).

[0243] Terminal 3051 and / or terminal 3041 may be portable devices such as laptops, tablets, smartphones, or any other suitable devices for receiving, storing, transmitting, and / or displaying relevant information.

[0244] Any information described above in relation to database 3011 and any other suitable information may be stored in memory 3015. One or more of the applications 3019 may include one or more algorithms that can be used to perform the functions of a continuous tank polymerization printer and to perform any other suitable tasks.

[0245] The apparatus and method may operate in conjunction with a number of other general-purpose or special-purpose computing system environments or configurations. Examples of well-known computing systems, environments, and / or configurations that may be suitable for use in conjunction with the present invention include, but are not limited to, personal computers, server computers, handheld or laptop devices, tablets, mobile phones, and / or other personal digital assistants ("PDAs"), multiprocessor systems, microprocessor-based systems, set-top boxes, programmable consumer electronics, network PCs, small computers, mainframe computers, distributed computing environments, and equivalents, including any of the systems or devices described above.

[0246] The apparatus and method may be described in the general context of computer executable instructions, such as program modules, executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform a specific task or implement a specific abstract data type. The present invention may also be practiced in a distributed computing environment, where tasks are performed by remote processing devices linked through a communication network. In a distributed computing environment, program modules may reside in both local and remote computer storage media, including memory storage devices.

[0247] Figure 31 shows an illustrative apparatus 3100 that may be configured according to the principles of the present invention.

[0248] The device 3100 may be a computing machine. The device 3100 may include one or more features of the device shown in Figure 30.

[0249] The apparatus 3100 may include a chip module 3102, which may include one or more integrated circuits, which may include logic configured to perform any other suitable logical operations.

[0250] The apparatus 3100 may include one or more of the following components: an I / O network 3104 which may include a transmitter device and a receiver device and may interface with an optical fiber cable, a coaxial cable, a telephone line, a wireless device, PHY layer hardware, a keypad / display control device, or any other suitable encoded medium or device; a peripheral device 3106 which may include a counter timer, a real-time timer, a power-on reset generator, or any other suitable peripheral device; a logic processing device 3108 which may solve equations and perform other methods described herein; and a machine-readable memory 3110.

[0251] The machine-readable memory 3110 may be configured to store machine-readable data structures, lens precursors, and any other suitable information or data structures associated with the continuous bath polymerization printer.

[0252] Components 3102, 3104, 3106, 3108, and 3110 may all be coupled together by a system bus or other interconnect 3112 and may be present on one or more circuit boards such as 3120. In some embodiments, the components may be integrated into a single chip.

[0253] The chip may be silicon-based.

[0254] The apparatus and method may involve modeling or testing the activation energy (Ec) and depth of penetration (Dp), or receiving modeled or test values thereof.

[0255] Such models may start from the conventional kinetic hardening of the polymerization process. Equation (1) states that the rate of change of monomer concentration [M] over time is the polymerization rate R p which may be defined as, and R i is stated to be the free radical initiation rate.

Number

[0256] The polymerization rate may be defined as follows.

Number

[0257] where k p is the kinetic rate constant for elongation, and [M * is the radical chain concentration. Adopting the steady state approximation (i.e., radical initiation equals termination), the following may be provided.

[0258]

Number

[0259] In the formula, k t This is the dynamical rate constant with respect to the termination. The initiation rate can be related to the photon flux I(z) as a function of depth z by the following:

number

[0260] During the ceremony, [ka] is the quantum yield, [PI] is the photoinitiator concentration {M}, and ∈ is the molar extinction coefficient {L⁻¹M⁻¹}.

[0261] The intensity at depth z can be derived from Beer's law.

number

[0262] Therefore, equation (4) can be expressed as follows:

number

[0263] Substituting equation (6) into equation (3) yields the following:

number

[0264] Equation (7) can be rewritten as follows:

number

[0265] Assuming that the terms inside the square root are independent of time, both sides of equation (8) can be used to obtain the following equation for the degree of polymerization:

number

[0266] In the formula, degree of polymerization [ka] It simply becomes the following:

number

[0267] Note that [M0] is the initial concentration of monomer [M] at time t=0. It may be desirable to define the polymerization range p from the viewpoint of the degree of polymerization, as follows.

number

[0268] Using equations (10) and (11), equation (8) can be rewritten as follows:

number

[0269] For the purpose of testing and modeling, a new parameter is introduced, as seen in equation (13). [ka] It may be desirable to define it.

number

[0270] Therefore, equation (12) can be rewritten as follows:

number

[0271] At the gel point, the extent of polymerization can be indicated by pc at a depth zc, where zc may correspond to the pre-gelled zone as referred to herein. The curing time is denoted as tc, which is also the duration of exposure time, during which the light source remains exposed to UV light on the resin. Using equation (14) with the parameters defined for the gel point above, equation (13) can be rewritten as follows:

number

[0272] Finding the logarithm of both sides of equation (15) gives us the following equation for hardening depth.

number

[0273] By examining equation (16), the competitive nature of the product of the molar extinction coefficient and the concentration of the photoinhibitor can be observed.

[0274] To maximize the hardening depth with respect to [PI], one may take the derivative of equation (16) with respect to [PI]. However, one may define a new parameter by noting that the product of [PI] and ∈ appears together.

number

number

[0275] Here, we maximize the curing depth. [ka] The value can be found.

number

[0276] Setting the derivative of the above equation to 0, the hardening depth is maximized as follows: [ka] An expression relating to the value of can be obtained.

number

[0277] Equation (15) has at least three known values ​​for which the current EcDp test requires input and provides output data: exposure time t in the image plane. c Both the light intensity I0 and the light intensity I0 can be inputs to the test approach. Each test specimen undergoes various exposure times, with a unique thickness z c A gelatinous square can be obtained.

[0278] In addition to the above, the photoinhibitor concentration [PI] and the molar quenching coefficient ∈ are likely to be known. Therefore, the following parameters can be obtained through regression analysis using equation (15). [Table 1]

[0279] If the photoinhibitor concentration and molar quenching value are unknown, regression analysis with respect to the following may be desired, along with equation (15). [Table 2]

[0280] A way to obtain higher fidelity in the test would be to vary the intensity of the EcDp test, i.e., I0. Additional variable intensity can provide higher fidelity to the determination of regression analysis parameters, which is useful in characterizing the curing process. The additional fidelity obtained in the parameter values ​​can be utilized in modeling the printing process itself. In equation (17), as follows: [ka] It may be desirable to use this to determine the regression analysis parameters. [Table 3]

[0281] Regression analysis may be performed using equation (15) and one or more of the inputs below to determine the unique parameters shown in Table 1-2. Alternatively, Table 3 may be adopted using equation (17). Tables 4 and 5 show two test schemes, where m is the test number and n is the subset variable in the test. Each test m may give n unique curing depths that have a constant intensity and increase over time with increasing exposure time.

[0282] A regression algorithm may be employed to determine the "best" fit for the regression analysis parameters. Once completed, a unique single value (beta, degree of hardening, molar extinction coefficient, and photoinhibitor concentration) can be obtained for each parameter. [Table 4] [Table 5]

[0283] One possible outcome of the above analysis and testing scheme is the ability to test various resin-photoinitiator combinations at different intensities and over multiple durations, and to obtain unique and valuable parameter values ​​for the system's recipe. These unique parameter values ​​can uniquely characterize the curing profile of the recipe.

[0284] Equation (17) described above is an equation relating to how gel thickness can evolve over time with respect to various strength levels. Therefore, by utilizing the material tests described above, it is possible to predict gel thickness evolution for any combination of resin material and projector variables such as photoinitiator concentration, strength, and exposure time.

[0285] A regression analysis algorithm may be used to take test inputs and determine parameters for any of the datasets, such as those in Tables 1-3. As an example, the test schemes required for the parameter systems in Table 3 are given in Table 5. For one recipe in Table 5, the regression analysis finds the "best" fit combination of beta, degree of hardening, and alpha values ​​that characterize the entire hardening profile, as seen in Figures 32 and 33.

[0286] The blue line in Figure 32 is the characteristic curing equation, which can predict the curing depth as a function of energy density, as explained by equation (17). The parameters obtained from the regression analysis depicted in Figure 33 may be used to generate a curing profile, compared to the actual data shown by the orange curve in Figure 32. Parameters [ka] , [ka] , p c The critical energy density, as a system, can be used to characterize the resin, photoinitiator, and UV light intensity.

[0287] For comparison, Figures 34 and 35 below show the results of similar tests and curing depth characteristic evaluation curves as in Figures 32 and 33. The difference between the two sets is that Figures 34 and 35 use the same resin as Figures 32 and 33, but the photoinhibitor concentration is increased by 0.8% to 1.2% by weight. The two system curves appear similar in nature, but they are not, as can be seen by examining the two sets of unique parameter sets in Figures 34 and 35.

[0288] Based on the resin, photoinitiator, and UV light intensity system, the way in which the material will evolve over time can be predicted. Furthermore, by understanding how any given material will evolve within the system, the characteristics and properties of the part of interest can be controlled and utilized. In particular, geometric part quality, dimensional accuracy, and unmolded part strength can be treated as functions of curing depth evolution, as shown in Section 6. This evolution can be utilized and regulated by one or more printer controls, including, in particular, printing speed, part orientation, and variable light intensity over time. Exemplary Embodiment Pre-gelation zone software embodiment 1. A non-transient computer-readable medium for storing instructions for producing optical lens bodies, wherein when the instructions are executed by a continuous tank polymerization printer, continuous tank polymerization is triggered. The steps include projecting radiation into the resin, The step of pulling the gel body away from the projector that provides radiation, A step of controlling the thickness of the pre-gelled zone extending from the resin to the gel body, A non-transient computer-readable medium that implements a method including the following. 2. In this method, the control step is: A step of receiving a thickness control value, The steps include setting the tensile ratio and obtaining the thickness corresponding to the thickness control value, The medium described in Embodiment 1, including the medium described in Embodiment 1. 3. The method further includes the step of setting the intensity of radiation corresponding to a thickness control value, as described in Embodiment 2 of the medium. 4. In this method, the control step is: A step of receiving a thickness control value, The steps include setting the tensile ratio and radiation intensity, and obtaining the thickness corresponding to the thickness control value, The medium described in Embodiment 1, including the medium described in Embodiment 1. 5. This method further includes a step of receiving resin activation energy corresponding to the resin, The setting is based on the activation energy. The medium described in Embodiment 2. 6. This method further includes the step of receiving the resin penetration depth corresponding to the resin, The settings are based on the depth of transmission. The medium described in Embodiment 2. 7. This method further, The process includes a step of receiving the complete curing value on the printer, The settings are based on the complete curing value on the printer. The medium described in Embodiment 2. 8. This method further, A step of receiving an indication corresponding to the observed pre-gelling zone thickness, The steps include adjusting the rate based on the observed pre-gelling zone thickness, The medium according to Embodiment 3, including the medium described above. 9. The printer includes an optical sensor configured to generate a signal corresponding to the observed pre-gelled zone thickness. The adjustment step includes the step of receiving a signal, The step of adjusting the rate is based on the signal. The medium described in Embodiment 8. 10. The method further includes the step of adjusting the strength based on the observed pre-gelled zone thickness, as described in Embodiment 8. 11. This method further includes a step of receiving an indication corresponding to the observed pre-gelled zone thickness, The step of adjusting the intensity is based on the observed pre-gelled zone thickness. The medium described in Embodiment 3. 12. This method further, Steps to receive indications corresponding to tension, observed forces, The steps include adjusting the rate based on the observed force, The medium according to Embodiment 3, including the medium described above. 13. The method further includes the step of adjusting the intensity based on the observed force, as described in Embodiment 12. 14. This method further includes the step of receiving an indication corresponding to the observed force, which corresponds to the tension. The step of adjusting the intensity is based on the observed force. The medium described in Embodiment 3. 15. The method according to Embodiment 1, wherein the pre-gelled zone thickness is defined as being parallel to the direction of tension. 16. The method according to Embodiment 15, wherein the pre-gelling zone thickness is defined as the adjacent portion of the gel body that is closest to the projector. 17. The method according to Embodiment 15, wherein the pre-gelling zone thickness is defined as being offset laterally with respect to the tensile direction from the portion of the gel body closest to the projector. 18. The method according to Embodiment 15, wherein the pre-gelling zone thickness is defined as the average of the pre-gelling zone thickness that varies laterally across the curved end of the gel body closest to the projector. 19. The method according to Embodiment 1, wherein the gel body stretches in a direction not perpendicular to the direction of tension. 20. The method according to Embodiment 1, wherein the gel body is stretched in a direction parallel to the direction of tension. 21. This method further, Each step involves receiving an offset value corresponding to the offset in the lateral direction relative to the tensile direction from the part of the gel body that is closest to the projector, For each offset, the step of receiving a thickness control value, The method according to Embodiment 15, wherein the step of controlling includes selecting one of the thickness control values ​​to be the thickness. 22. This method further, Each step involves receiving an offset value corresponding to the offset in the lateral direction relative to the tensile direction from the part of the gel body that is closest to the projector, For each offset, the step of receiving a thickness control value, The method according to Embodiment 15, which includes, and the step of controlling, includes selecting an average control value for the thickness to be the thickness. 23. In this method, the main body is the medium described in Embodiment 1, which is a green body. twenty four. This method further, The total length of the body, corresponding to the planned length of the body to be printed, Peripheral percentage corresponding to the planned length of the edge, The step of receiving, A step to detect when the pre-gelled zone reaches the edge, The medium according to Embodiment 1, which includes, and the control step includes reducing the thickness when the pre-gelled zone reaches the edge. 25. In this method, the planned length corresponds to the length of the lens precursor, as described in Embodiment 24. 26. In this method, the planned length corresponds to the combined length of the lens precursor and the excess periphery configured for post-printing removal, as described in Embodiment 24 of the medium. 27. This method further, The total length of the body, corresponding to the planned length of the body to be printed, Peripheral percentage corresponding to the planned length of the edge, Includes the step of receiving, The control steps are: The first value corresponds to the edge, During curing for the planned length, the second value exceeds the first value, This includes a step of maintaining the thickness, The medium described in Embodiment 1. 28. In this method, the planned length corresponds to the length of the lens precursor, in the medium described in Embodiment 27. 29. The present method is the medium according to Embodiment 27, wherein the planned length corresponds to the combined length of the lens precursor and the excess periphery configured for post-printing removal. 30. In this method, the radiation is the first radiation, The method further includes a step of projecting a second radiation onto a portion of the gel body, configured to activate a photoactivation curing blocker and prevent curing. The medium described in Embodiment 1. 31. A non-transient computer-readable medium for storing instructions for producing optical lens bodies, wherein when the instructions are executed by a continuous tank polymerization printer, continuous tank polymerization is triggered. The steps include projecting radiation into the resin, The steps include: pulling the gel body away from the projector that provides radiation, the pulling generating a force acting in the opposite direction to the direction of the pull; A step of controlling force and obtaining the thickness of the pre-gelled zone, wherein the pre-gelled zone extends from the resin to the gel body, A non-transient computer-readable medium that implements a method including the following. 32. In this method, the control step is: The steps include receiving force control values, The steps include setting the tensile ratio and obtaining the force corresponding to the force control value, The medium described in Embodiment 31, including the medium described in Embodiment 31. 33. The method further includes the step of setting the intensity of radiation corresponding to a force control value, as described in Embodiment 32. 34. In this method, the control step is: The steps include receiving force control values, The steps include setting the tensile ratio and radiation intensity, and obtaining the force corresponding to the force control value, The medium according to embodiment 32, including the medium described above. 35. This method further includes a step of receiving resin activation energy corresponding to the resin, The setting is based on the activation energy. The medium described in Embodiment 32. 36. This method further includes the step of receiving the resin penetration depth corresponding to the resin, The settings are based on the depth of transmission. The medium described in Embodiment 32. 37. This method further, The process includes a step of receiving the complete curing value on the printer, The settings are based on the complete curing value on the printer. The medium described in Embodiment 32. 38. This method further, A step of receiving an indication corresponding to the observed pre-gelling zone thickness, The steps include adjusting the rate based on the observed pre-gelling zone thickness, The medium according to embodiment 32, including the medium described above. 39. The method further includes the step of adjusting the strength based on the observed pre-gelled zone thickness, as described in Embodiment 33. 40. This method further includes a step of receiving an indication corresponding to the observed pre-gelled zone thickness, The step of adjusting the intensity is based on the observed pre-gelled zone thickness. The medium described in Embodiment 33. 41. This method further, Steps to receive indications corresponding to tension, observed forces, The steps include adjusting the rate based on the observed force, The medium according to embodiment 32, including the medium described above. 42. The method further includes the step of adjusting the intensity based on the observed force, according to Embodiment 33 of the medium. 43. This method further includes the step of receiving an indication corresponding to the observed force, which corresponds to the tension. The step of adjusting the intensity is based on the observed force. The medium described in Embodiment 33. 44. The printer includes an interface and a collimating lens configured to collimate radiation entering the interface. In this method, the tensile force includes the step of moving a construction platform such that the gel body is attached thereto in a first direction perpendicular to the interface and a second direction parallel to the interface. The medium described in Embodiment 33. Aberration mitigation embodiment 1. A non-transient computer-readable medium for storing instructions for producing optical lens bodies, wherein when the instructions are executed by a continuous tank polymerization printer, continuous tank polymerization is triggered. The steps include projecting pixelated radiation into the resin, The step of pulling the gel body away from the projector that provides radiation, A step of controlling the beam characteristics of each pixel in the pixelated radiation, A non-transient computer-readable medium that implements a method including the following. 2. In this method, The projection step includes reflecting the source light beam from a digital micromirror device having a plurality of micromirrors, each of which is individually controllable. Each pixel corresponds to one of the micromirrors. The medium described in Embodiment 1. 3. In this method, the beam characteristics, including radiant intensity, are those of the medium described in Embodiment 1. 4. The printer includes an interface that defines a plane. In this method, the control step includes varying the intensity of radiation as a function of time and location along a plane. The medium described in Embodiment 3. 5. In this method, the beam characteristics are the angular distribution of intensity, as described in Embodiment 1. 6. The printer includes an interface that defines a plane. In this method, the control step includes a step of changing the angular distribution. The medium described in Embodiment 5. 7. The printer includes a projector configured to project light, which has an adjustable focal length. In this method, the steps to be changed include the step of adjusting the focal length. The medium described in Embodiment 6. 8. The method, in which the adjustment step includes moving the focal plane of light away from the incident surface of the collimating lens, is described in Embodiment 7 for the medium. 9. The method is described in Embodiment 7, wherein the step of altering includes the step of sharpening the distribution of the medium. 10. The present method, in which the step of altering includes the step of flattening the distribution, is the medium according to Embodiment 7. 11. In this method, The first pixel has a first angular distribution of intensity, The second pixel, positioned next to the first pixel, has a second angular distribution of intensity. The altering step includes overlapping the first and second angular distributions of intensity such that the radiation entering the resin has a maximum spatial intensity variation of less than or equal to a predetermined percentage of the average intensity of all pixels. The medium described in Embodiment 7. 12. In this method, the selected percentage is 20%, as described in Embodiment 11. 13. In this method, the selected percentage is 15%, as described in Embodiment 11. 14. In this method, the selected percentage is 10% of the medium as described in Embodiment 11. 15. In this method, the intensity angular distribution conforms to the optical goniometer profile of the medium described in Embodiment 5. 16. In this method, The angular distribution has the maximum intensity, The maximum intensity defines the pixel angle. The medium described in Embodiment 5. 17. The method, in which the control step includes the step of varying the pixel angle over time, is as described in Embodiment 16. 18. The printer includes a collimating lens, a projector, and an interface that defines a plane. This method includes the step of displacing the collimating lens parallel to the plane relative to the projector. The medium described in Embodiment 17. 19. The present method, in which the displacement step includes moving the collimating lens in a pattern, is the medium described in Embodiment 18. 20. In this method, the pattern is periodic, as described in Embodiment 18. 21. In this method, the pattern is linear, as described in Embodiment 19. 22. In this method, the pattern is elliptical, as described in Embodiment 19. 23. The present method is a medium according to Embodiment 19, wherein the pattern is periodic and has an amplitude of half the pixel diameter. twenty four. The printer includes a collimating lens, a projector, and an interface that defines a plane. This method includes the step of displacing the projector parallel to the plane relative to the collimating lens. The medium described in Embodiment 17. 25. In this method, the control step includes the step of receiving a radiation command for each pixel, wherein the radiation command is a medium according to Embodiment 1, corresponding to the beam characteristics. 26. The medium according to Embodiment 25, wherein, when defined within the lens body, a series of predefined cross-sections exist within the lens body. 27. In this method, Each cross-section is bounded by a first surface and a second surface. The first surface corresponds to the first surface of the lens body, The second surface corresponds to the second surface of the lens body. The first surface is defined in the Signed Distance Field file, The medium described in Embodiment 25. 28. The method further includes the step of receiving a shape corresponding to a second surface of the lens body, as described in Embodiment 27. 29. The present method, in which the step of receiving the shape includes receiving the power value of the lens, is described in Embodiment 28. 30. The method further comprises the medium according to Embodiment 27, wherein, when the Signed Distance Field file is a first Signed Distance Field file, the step of receiving a shape includes the step of receiving a second Signed Distance Field file that defines a second shape. 31. The printer includes a mask that is outside the peripheral area and is configured to block light from the projector. This method further allows for the following in each cross-section: The first surface and The second surface and The step includes constructing a mask so as to conform to it, The medium described in Embodiment 27. 32. This method further provides the following information for each cross-section: The first edge between the first surface and the second surface, The second edge between the first surface and the second surface, The medium according to embodiment 27, comprising the step of constructing a mask to conform to the medium. 33. In this method, radiated instructions are contained within a stack of 2D radiated instructions, each corresponding to one of the cross-sections. The receiving step includes the step of receiving the stack. The medium described in Embodiment 26. 34. The medium according to Embodiment 33, further comprising the step of receiving an aberration mitigation command configured to mitigate structural defects arising from the emission pattern of pixels. 35. In this method, the aberration mitigation command is aligned to one of the cross-sections of the medium according to Embodiment 34. 36. In this method, the aberration mitigation command is one of a plurality of aberration mitigation commands corresponding to different cross-sections, as described in Embodiment 35. 37. The printer includes a collimating lens and a projector. In this method, the aberration reduction command corresponds to the relative motion of the collimating lens and the projector. The medium described in Embodiment 36. 38. The printer includes a collimating lens and a projector. In this method, the aberration reduction command corresponds to the offset between the focal plane of the light to be emitted from the projector and the incident surface of the collimating lens. The medium described in Embodiment 36. 39. In this method, the stack of two-dimensional radiated instructions is embodied in a Signed Distance Field ("SDF") file, as described in Embodiment 33. 40. The medium described in Embodiment 39, which is configured to be input into an optical lens cutting machine, is an SDF file. 41. The method, according to Embodiment 25, comprises a step of providing radiation to a resin in accordance with a radiation command. 42. The present method, in which the control step includes the step of providing radiation to the resin in accordance with the SDF file, is the medium described in Embodiment 41. 43. In this method, the control step is: A radiation order and Aberration mitigation order and SDF file and, A medium according to embodiment 34, comprising the step of providing radiation to a resin in accordance with the Pre-gelation zone thickness - Method embodiment 1. A method for forming an optical lens green body using a sustained-cycle polymerization printer, wherein the sustained-cycle polymerization printer is equipped with a radiation source, Projecting radiation from the radiation source through the first side of the interface layer, The resin is cured on a second side of the interface layer until a pre-gelling zone is formed, wherein the second side faces the first side, and the pre-gelling zone comprises a proximal initial curing zone of the interface layer and a distal shape-retaining zone of the interface layer. The pre-gelled zone is grown to a thickness of 300 microns, Maintain the pre-gelled zone to a thickness of 300 microns or more until the green body obtains multiple predetermined dimensions. Methods that include... 2. The method according to Embodiment 1, wherein the plurality of predetermined dimensions correspond to the plurality of predetermined optical lens precursor dimensions. 3. The method according to Embodiment 1, wherein projecting radiation from a radiation source includes projecting ultraviolet (UV) light radiation upward through an interface layer using a digital light processing (DLP) projector. 4. Projecting radiation from a radiation source includes projecting ultraviolet (UV) light radiation upward through an interface layer using a digital light processing (DLP) projector, wherein the UV light radiation is collimated by adding a collimating lens prior to reaching the initial curing zone, according to Embodiment 1. 5. The optical lens green body comprises two lenses formed together as an integrated component, each of which comprises a discrete prescription and a discrete ocular center, the discrete ocular centers being different in distance from the center line of the integrated component, according to Embodiment 1. 6. The method according to Embodiment 5, wherein each of the two lenses is formed with a connecting device for attaching it to frame hardware. 7. The method according to Embodiment 1, wherein projecting radiation from a radiation source involves using an array formed of multiple projectors, each of which is configured to project ultraviolet (UV) light radiation upward through an interface layer. Hard coating apparatus embodiment 1. An optical lens, The main body layer, including the main body layer portion, A coating layer including the coating layer portion, The transition area between the main body layer and the coating layer, Equipped with, In the transition region, the main layer is covalently bonded to the coating layer, forming an optical lens. 2. The transition portion has a thickness of 25 to 75 nanometers, as described in Embodiment 1. 3. The transition portion is an optical lens according to Embodiment 1, having a thickness of approximately 50 nanometers. 4. The optical lens according to Embodiment 1, wherein the coating layer is an anti-reflective ("AR") layer. 5. The optical lens according to Embodiment 1, wherein the coating layer is an abrasion-resistant layer. 6. The optical lens according to Embodiment 1, wherein the first coating layer is applied prior to the post-printing curing step. 7. The optical lens according to Embodiment 6, wherein the second coating layer is applied after the post-printing curing step. 8. The optical lens according to Embodiment 6, wherein the second coating layer is applied after the polishing step. 9. The optical lens according to Embodiment 1, wherein the coating layer is applied using a spin coating method. 10. The optical lens according to Embodiment 1, wherein the coating layer is applied using an immersion coating method. 11. The optical lens according to Embodiment 1, wherein the coating layer is refractive mismatched. 12. The optical lens according to Embodiment 1, wherein the coating layer is applied using ultraviolet (UV) radiation. Embodiment of a hard coating method 1. A method for coating the main body layer of an optical lens, wherein the main body layer comprises a main body layer portion, A step to cure the main layer of the optical lens to a point less than complete curing, A step of placing the main body layer in an environment where a coating layer material for forming a coating layer is present, wherein the coating layer material comprises a coating layer portion, A step of covalently bonding a main body layer to a coating layer using radiation, wherein a transition zone is formed between the main body layer and the coating layer in response to the use of radiation. Includes, In the transition region, the main layer is covalently bonded to the coating layer. 2. The method according to Embodiment 1, wherein the transition region has a thickness of 25 to 75 nanometers. 3. The method according to Embodiment 1, wherein the transition region has a thickness of approximately 50 nanometers. 4. The method according to Embodiment 1, wherein the coating layer is an anti-reflective ("AR") layer. 5. The method according to Embodiment 1, wherein the coating layer is an abrasion-resistant layer. 6. The method according to Embodiment 1, wherein the first coating layer is applied prior to the post-printing curing step. 7. The method according to Embodiment 6, wherein the second coating layer is applied after the post-printing curing step. 8. The method according to Embodiment 6, wherein the second coating layer is applied after the polishing step. 9. The method according to Embodiment 1, wherein the coating layer is applied using a spin coating method. 10. The method according to Embodiment 1, wherein the coating layer is applied using an immersion coating method. 11. The method according to Embodiment 1, wherein the coating layer is refractive mismatched. 12. The method according to Embodiment 1, wherein the coating layer is applied using ultraviolet (UV) radiation.

Claims

1. It is an optical lens, The main body layer, including the main body layer portion, A coating layer including the coating layer portion, The transition portion between the main body layer and the coating layer Equipped with, In the transition section, the main body layer is covalently bonded to the coating layer, forming an optical lens.

2. The transition portion is an optical lens according to Embodiment 1, having a thickness of 25 to 75 nanometers.

3. The transition portion is an optical lens according to Embodiment 1, having a thickness of approximately 50 nanometers.

4. The optical lens according to Embodiment 1, wherein the coating layer is an anti-reflective ("AR") layer.

5. The optical lens according to Embodiment 1, wherein the coating layer is an abrasion-resistant layer.

6. The optical lens according to Embodiment 1, wherein the first coating layer is applied prior to the post-printing curing step.

7. The optical lens according to Embodiment 6, wherein the second coating layer is applied after the post-printing curing step.

8. The optical lens according to Embodiment 6, wherein the second coating layer is applied after the polishing step.

9. The optical lens according to Embodiment 1, wherein the coating layer is applied using a spin coating method.

10. The optical lens according to Embodiment 1, wherein the coating layer is applied using an immersion coating method.

11. The optical lens according to Embodiment 1, wherein the coating layer is refractive mismatched.

12. The optical lens according to Embodiment 1, wherein the coating layer is applied using ultraviolet (UV) radiation.

13. A method for coating the main body layer of an optical lens, wherein the main body layer comprises a main body layer portion, and the method is The main body layer of the optical lens is cured to a degree less than complete curing, The main body layer is placed in an environment, wherein a coating layer material for forming a coating layer is present in the environment, and the coating layer material comprises a coating layer portion. The method involves using radiation to covalently bond the main body layer to the coating layer, wherein a transition zone is formed between the main body layer and the coating layer in response to the use of radiation. Includes, In the transition section, the main body layer is covalently bonded to the coating layer.

14. The transition portion has a thickness of 25 to 75 nanometers, according to the method of Embodiment 1.

15. The transition portion has a thickness of approximately 50 nanometers, according to the method of Embodiment 1.

16. The method according to Embodiment 1, wherein the coating layer is an anti-reflective ("AR") layer.

17. The method according to Embodiment 1, wherein the coating layer is an abrasion-resistant layer.

18. The method according to Embodiment 1, wherein the first coating layer is applied prior to the post-printing curing step.

19. The method according to Embodiment 18, wherein the second coating layer is applied after the post-printing curing step.

20. The method according to Embodiment 18, wherein the second coating layer is applied after the polishing step.

21. The method according to Embodiment 1, wherein the coating layer is applied using a spin coating method.

22. The method according to Embodiment 1, wherein the coating layer is applied using an immersion coating method.

23. The method according to Embodiment 1, wherein the coating layer is refractive mismatched.

24. The method according to Embodiment 1, wherein the coating layer is applied using ultraviolet (UV) radiation.

25. A non-transient computer-readable medium for storing instructions for producing an optical lens body, wherein when the instructions are executed by a continuous tank polymerization printer, the continuous tank polymerization is triggered, the method is carried out, and the method is Projecting radiation into the resin, Pulling the gel body away from the projector that provides the radiation, Controlling the thickness of the pre-gelled zone extending from the resin to the gel body. Non-transient computer-readable media, including [specific examples of such media].

26. A non-transient computer-readable medium for storing instructions for producing an optical lens body, wherein when the instructions are executed by a continuous tank polymerization printer, the continuous tank polymerization is triggered, the method is carried out, and the method is Projecting pixelated radiation into resin, Pulling the gel body away from the projector that provides the radiation, Controlling the beam characteristics of each pixel in the pixelated radiation Non-transient computer-readable media, including [specific examples of such media].

27. A method for forming an optical lens green body using a sustained-tank polymerization printer, wherein the sustained-tank polymerization printer comprises a radiation source, and the method is Projecting radiation from the radiation source through the first side of the interface layer, The resin is cured on the second side of the interface layer until a pre-gelling zone is formed, wherein the second side faces the first side, and the pre-gelling zone comprises a proximal initial curing zone of the interface layer and a distal shape-retaining zone of the interface layer. The aforementioned pre-gelled zone is grown to a thickness of 300 microns, The pre-gelled zone is maintained to a thickness of 300 microns or more until the green body acquires a plurality of predetermined dimensions. Methods that include...

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