A method for additively manufacturing an ophthalmic device and a manufacturing system configured to perform such a method

Abstract

The present disclosure provides a method for additively manufacturing an ophthalmic device defined by an outer surface, the method comprising: a step (102) of inkjet printing at least one first core layer having at least one predetermined first thickness; a step (103) of inkjet printing at least one second core layer having at least one predetermined second thickness equal to or different from the predetermined first thickness at least partially on the at least one first core layer; and a step (104) of inkjet printing at least one edge layer on the at least one first core layer and adjacent to the at least one second core layer, wherein the at least one edge layer has at least one predetermined third thickness which is less than or equal to at least one predetermined second thickness and at least partially defines the outer surface of the ophthalmic device.

Description

Technology Field

[0001] The present disclosure relates to a method for additively manufacturing an ophthalmic device and a manufacturing system configured to perform such a method.

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

[0003] The present disclosure also relates to a computer program comprising instructions configured to implement additive manufacturing of such method when the computer program is executed by a computer, and a client-server communication interface for transmitting at least manufacturing data determined by a computer program that implements at least part of such method when the computer program is executed in a command and control unit to a remote computer, wherein the remote computer implements other parts of such method. Background Technology

[0004] It is known that additive manufacturing technology is used to manufacture ophthalmic devices such as eyeglass lenses.

[0005] Known methods for additive manufacturing of ophthalmic lenses, such as stereolithography and variations thereof, include a curing step and a lamination step performed sequentially in a manufacturing system comprising a curing device, a lamination device, and a building platform positioned in relation to a container filled with a predetermined material.

[0006] For example, each ophthalmic lens is constructed layer by layer on a construction platform that is movable relative to a container containing a predetermined volume of material. The construction platform is positioned at a predetermined location, and a curing device including an irradiator performs a curing step of the first layer of material, and a lamination device performs a lamination step by at least displacement of the construction platform so that a new layer of material having a predetermined thickness can be cured.

[0007] In other words, in these known methods, a curing step is performed on a layer that is liquid, for example, for a plurality of ophthalmic lenses to be manufactured on a construction platform. Thus, the liquid layer is cured, and a lamination step is performed to form a new liquid layer on the previously cured layer of the plurality of ophthalmic lenses to be manufactured next.

[0008] Another method of additive manufacturing may include the step of continuously depositing droplets of liquid material to form layers of material and curing them. This method, commonly referred to as 3D printing or inkjet printing, generally controls the shape of the layers by controlling the position and volume of the deposited droplets, while the curing step is often performed entirely. Other additive manufacturing methods may also be used.

[0009] In the above methods, multiple layers are formed, and some features referred to as stepped steps may be formed at the free ends of the layers adjacent to the contour of the ophthalmic device. The problem to be solved

[0010] Therefore, there is a need to provide a method for additively manufacturing an ophthalmic device with limited stepped steps by inkjet printing. means of solving the problem

[0011] The present disclosure relates to a method for additively manufacturing an ophthalmic device that is simple and convenient to perform, for example, by inkjet printing.

[0012] Accordingly, the present disclosure provides a method for additively manufacturing an ophthalmic device defined by an outer surface, the method comprising the steps of: inkjet printing at least one first core layer having at least one predetermined first thickness; inkjet printing at least one second core layer having at least one predetermined second thickness equal to or different from the predetermined first thickness at least partially on the at least one first core layer; and inkjet printing at least one edge layer on the at least one first core layer and adjacent to the at least one second core layer, wherein the at least one edge layer has at least one predetermined third thickness which is less than or equal to at least one predetermined second thickness and at least partially defines the outer surface of the ophthalmic device.

[0013] By the method according to the present disclosure, inkjet printing can be accurately controlled at the peripheral joint between two or more continuous layers, and thus the outer surface of an ophthalmic device can be smoothed by at least one dedicated edge layer having a thickness less than or equal to the thickness of a layer to which at least one edge layer is also formed and an optional layer to which at least one edge layer is also formed.

[0014] In other words, the method according to the present disclosure enables the provision of an ophthalmic device having an outer surface as close as possible to a final outer surface, in which there is no stepped step or the stepped step is reduced on the outer surface of the ophthalmic device by means of 3D inkjet printing technology.

[0015] The advantageous and convenient features of the manufacturing method are described below.

[0016] The method may include the step of partially curing at least one first core layer and / or at least one second core layer before inkjet printing at least one edge layer.

[0017] The method may include the steps of: inkjet printing at least one third core layer having at least one predetermined fourth thickness that is the same as or different from at least one of a predetermined first thickness, a predetermined second thickness, and a predetermined third thickness, at least partially on at least one second core layer; and inkjet printing at least one edge layer at least partially simultaneously with or at least partially continuously with inkjet printing the at least one third core layer.

[0018] In other words, inkjet printing of at least one edge layer around at least one second core layer can be performed at least partially continuously with respect to inkjet printing of the second core layer.

[0019] At least one edge layer may include several sub-edge layers of similar or different thicknesses.

[0020] Sub-edge layers can be at least partially juxtaposed and / or at least partially overlapped.

[0021] Sub-edge layers can be inkjet printed at least partially simultaneously and / or at least partially continuously with respect to each other.

[0022] At least one edge layer may have a closed loop shape around at least one second core layer.

[0023] For example, at least one edge layer may have a ring shape.

[0024] For example, at least one edge layer may have a shape corresponding to the final shape of the ophthalmic device, including the shape of the eyeglass frame.

[0025] The step of inkjet printing at least one first core layer and at least one second core layer can be performed with core print characteristics, while the step of inkjet printing at least one edge layer is performed with edge print characteristics that are at least partially distinct from the core print characteristics.

[0026] The step of inkjet printing at least one third core layer can also be performed with core print characteristics that are at least partially distinct from edge print characteristics.

[0027] Core print characteristics may be fixed or variable during inkjet printing of at least one first, second, or third core layer.

[0028] Edge print characteristics may be fixed or variable while inkjet printing at least one edge layer.

[0029] Each of the core print characteristics and edge print characteristics may include a core ink material and / or core droplet density and / or core droplet volume and / or core droplet viscosity and / or core droplet ejection rate, and each edge ink material and / or edge droplet density and / or edge droplet volume and / or edge droplet viscosity and / or edge droplet ejection rate.

[0030] The step of inkjet printing at least one third core layer may also include a core ink material and / or a core droplet density and / or a core droplet volume and / or a core droplet viscosity and / or a core droplet ejection rate.

[0031] The step of inkjet printing at least one first core layer and at least one second core layer can be performed by a core print head, while the step of inkjet printing at least one edge layer can be performed by an edge print head separate from the core print head.

[0032] The step of inkjet printing at least one third core layer can also be performed by a core print head.

[0033] The method may include the step of determining a manufacturing file comprising geometric characteristics of a sliced ​​ophthalmic device representing at least a first core layer, a second core layer, and at least one edge layer forming the outer surface of the ophthalmic device at a peripheral junction between a first core layer and a second core layer.

[0034] The manufacturing file may include parameters defined by a plurality of images representing a voxel distribution or droplet distribution, respectively, used to activate and deactivate the nozzles of the print head(s).

[0035] Images can be used alone or in combination and can be determined by at least one mathematical function, such as a linear, power, polynomial, exponential, logarithmic, sine curve, etc., which enables defining the "shape" of a stepped step to be filled, for example.

[0036] The present disclosure also provides, according to a second embodiment, a command and control unit, wherein the command and control unit comprises system elements configured to execute a computer program for additively manufacturing an ophthalmic device defined by an outer surface by implementing the steps of: inkjet printing at least one first core layer having at least one predetermined first thickness; inkjet printing at least one second core layer having at least one predetermined second thickness equal to or different from the predetermined first thickness at least partially on the at least one first core layer; and inkjet printing at least one edge layer on the at least one first core layer and adjacent to the at least one second core layer, wherein at least one edge layer at least partially defines the outer surface of the ophthalmic device and has at least one predetermined third thickness less than or equal to at least one predetermined second thickness.

[0037] According to a third embodiment, the present disclosure also provides a manufacturing system comprising an inkjet printer having at least one inkjet print head having a plurality of nozzles and a command and control unit, wherein the system is configured to additively manufacture an ophthalmic device defined by an outer surface by the steps of: inkjet printing at least one first core layer having at least one predetermined first thickness; inkjet printing at least one second core layer having at least one predetermined second thickness equal to or different from the predetermined first thickness at least partially on the at least one first core layer; and inkjet printing at least one edge layer on the at least one first core layer and adjacent to the at least one second core layer, wherein the at least one edge layer at least partially defines the outer surface of the ophthalmic device and has at least one predetermined third thickness less than or equal to at least one predetermined second thickness.

[0038] The present disclosure also provides, according to a fourth embodiment, a computer program, wherein the computer program comprises instructions configured to additively manufacture an ophthalmic device defined by an outer surface by implementing, when the computer program is executed by a computer, the steps of: inkjet printing at least one first core layer having at least one predetermined first thickness; inkjet printing at least one second core layer having at least one predetermined second thickness equal to or different from the predetermined first thickness; and inkjet printing at least one edge layer on the at least one first core layer and adjacent to the at least one second core layer, wherein at least one edge layer has at least one predetermined third thickness which is less than or equal to at least one predetermined second thickness and at least one predetermined thickness.

[0039] The present disclosure also, according to a fifth embodiment, provides a client-server communication interface, wherein the client-server communication interface transmits to a remote computer at least manufacturing data for additively manufacturing an ophthalmic device defined by an outer surface, such as a manufacturing file comprising geometric characteristics of a sliced ​​ophthalmic device, including at least one first core layer, at least one second core layer, and at least one edge layer forming an outer surface of the ophthalmic device at a peripheral junction between at least one first core layer and at least one second core layer, which are determined by the computer program when the computer program is executed in a command and control unit; and the remote computer is configured to implement the steps of: inkjet printing at least one first core layer having at least one predetermined first thickness; inkjet printing at least one second core layer having at least one predetermined second thickness equal to or different from the predetermined first thickness at least partially on the at least one first core layer; and inkjet printing at least one edge layer on the at least one first core layer and adjacent to the at least one second core layer. At least one edge layer partially defines the outer surface of the ophthalmic device and has at least one predetermined third thickness which is less than or equal to at least one predetermined second thickness. Effects of the invention

[0040] Included in the contents of the present invention. Brief explanation of the drawing

[0041] The description of the present disclosure now continues with reference to the accompanying drawings and detailed descriptions of embodiments provided below as non-limiting examples. Figure 1 is a schematic diagram of a manufacturing system configured to perform a method of additive manufacturing of ophthalmic devices. FIG. 2 schematically illustrates a client-server communication interface comprising system parts configured to transmit at least one configuration parameter determined by a method according to the present disclosure to a remote data processing system. FIG. 3 is a block diagram illustrating the steps of a method for manufacturing an ophthalmic device by additive manufacturing according to the present disclosure. FIG. 4 is a schematic diagram illustrating a method performed according to a first embodiment. Figure 5 illustrates images having different voxel distributions. FIG. 6 is a schematic diagram illustrating a method performed according to a second embodiment. FIGS. 7 through 9 illustrate different images having different voxel distributions that can be used to perform the method illustrated in FIG. 4. Figure 10 illustrates details of images based on different droplet densities and droplet volumes. Specific details for implementing the invention

[0042] FIG. 1 schematically illustrates a manufacturing system (1) configured to perform a method of additively manufacturing each ophthalmic device (2) defined by each outer surface (10).

[0043] In the illustrated embodiment, the manufacturing system (1) is a lamination system configured to manufacture an ophthalmic device (2) layer by layer, and each layer (3) is formed by the volume of a predetermined material (11) that is at least partially polymerized and cured.

[0044] In this regard, the manufacturing system (1) includes an additive manufacturing module, also referred to as such, which comprises an additive unit formed by an inkjet printer (4) configured to project at least one predetermined volume of a droplet-shaped material.

[0045] At least one predetermined material is suitable for manufacturing an ophthalmic device (2), such as a liquid resin for making glasses.

[0046] The inkjet printer (4) includes a plurality of inkjet print heads (6i) each having a plurality of nozzles (8) through which a predetermined material is projected as a droplet jet (9), or a single inkjet print head.

[0047] A droplet jet includes droplets that can be considered as the volume of at least one material without a tail or satellite.

[0048] Each print head (6i) has a predetermined number of nozzle(s) (8) and a predetermined arrangement thereof. The nozzles (8) can be activated or deactivated.

[0049] The inkjet printer (4) further includes at least one curing device (11) comprising a radiator configured to perform curing steps, for example.

[0050] In other words, the curing device (11) can cure droplets of material previously formed by the nozzles (8).

[0051] The inkjet printer (4) may further include a command and control unit (7) comprising system elements configured to execute a computer program including instructions configured to implement at least some steps of an additive manufacturing method according to the present disclosure for manufacturing an ophthalmic device (2).

[0052] The command and control unit (7) may be configured to command and control a print head resolution corresponding to the radial resolution of at least the print head(s) (6i) defined as a function of the number and arrangement of the print head(s) (6i) and, in particular, the nozzles (8).

[0053] The command and control unit (7) may be configured to command and control the activation and / or deactivation of each nozzle (8) and, if present, the injection frequency of each nozzle.

[0054] The nozzle spray frequency can be variable or fixed.

[0055] The nozzle spray frequency may depend at least on the geometric characteristics of the ophthalmic device (2) to be manufactured and / or the position including the inclination and radial movement with respect to the manufacturing axis (MA) of the print head(s).

[0056] The inkjet printer (4) is configured to be located above the support member (5) and to form layers (3) on the support member (5) by building core layers (3a) and edge layers (3b) at peripheral joints between adjacent core layers.

[0057] Depending on the outer surface (10) to be obtained for the ophthalmic device (2), edge layers (3b) may form a major part of this outer surface (10).

[0058] The command and control unit (7) can be configured to position the print head(s) (6i) at a selected distance value among a plurality of distance values ​​from the support member (5).

[0059] The distance value is included in the minimum height at which a predetermined material can form a droplet to the maximum height at which a droplet of the predetermined material is accurately formed on the support member (5).

[0060] The support member (5) can rotate about a rotation axis corresponding to the manufacturing axis (MA), and the print head(s) (6i) and the support member (5) can be inclined relative to each other and / or the print head(s) (6i) can be inclined relative to the manufacturing axis (MA).

[0061] In this regard, the command and control unit (7) may also be configured to command and control the angle of inclination of the print head(s) (6i) and the support member (5) relative to each other and the rotational speed of the support member (5) around the manufacturing axis (MA).

[0062] Additionally, the command and control unit (7) may be configured to command and control the print resolution of the print head(s) (6i), including a process resolution corresponding to an angle resolution defined as a function of at least the nozzle injection frequency and the print head resolution as defined above.

[0063] In particular, the command and control unit (7) may be configured to define a so-called sliced ​​ophthalmic device by providing a manufacturing file or parameters from the file to the print head(s) (6i), which includes geometric characteristics representing the core layers (3a) and edge layers (3b) of the ophthalmic device (2).

[0064] The parameters of the manufacturing file may include multiple images representing a voxel distribution or a droplet distribution, respectively.

[0065] In other words, the images determine the activated and deactivated nozzles (8) of the print head(s) (6i).

[0066] The images can be determined by at least one mathematical function that defines the "shape" of the stepped step to be filled.

[0067] Different types of mathematical functions, such as linear, power, polynomial, exponential, logarithmic, and sine curves, can be used alone or in combination.

[0068] Depending on the geometric characteristics of the ophthalmic device to be manufactured, including the external surface to be obtained and, more generally, the curvature, various images obtained based on various mathematical functions may be used.

[0069] Accordingly, each core layer (3a) and / or each edge layer (3b) may be defined by one or more images according to the geometric characteristics of the layer itself and / or core print characteristics and / or edge print characteristics and / or print resolution and / or process resolution defined above.

[0070] Core print characteristics may include core ink material and / or core droplet density and / or core droplet volume and / or core droplet viscosity and / or core droplet ejection rate, and edge print characteristics may include edge ink material and / or edge droplet density and / or edge droplet volume and / or edge droplet viscosity and / or edge droplet ejection rate.

[0071] FIG. 2 illustrates a client-server communication interface (24) comprising, for example, a so-called provider side (29a) and a so-called other client side (29b), wherein these two sides communicate through an internet interface (28).

[0072] The provider side includes a data processing system of the same type as the command and control unit (7) disclosed in FIG. 1 or a server (29a) connected to the command and control unit (27a), and the server (29a) is configured to communicate with an internet interface (28).

[0073] The client side (29b) is configured to communicate with the internet interface (28) and is connected to a data processing system or command and control unit (27b) of the same type as the provider side.

[0074] Additionally, the client-side command and control unit (27b) is connected to a manufacturing system (1b) of the same type as in FIG. 1 to manufacture an ophthalmic device (2b) using layer-by-layer (3b) processing by an inkjet printer as described above.

[0075] For example, the client-side command and control unit (27b) is configured to allow the user to receive some parameters regarding the manufacturing method to be implemented for manufacturing the ophthalmic device, the inkjet printer, and the ophthalmic device (2b) through additive manufacturing.

[0076] The client-side command and control unit (27b) uses the internet (28) and server (29a) interfaces to transmit the received data to the supplier-side command and control unit (27a) to determine the manufacturing file and operation parameters as described above.

[0077] A command and control unit (27a) on the supplier side executes a computer program included in the command and control unit to implement some steps of a method for additively manufacturing an ophthalmic device.

[0078] The supplier-side command and control unit (27a) transmits manufacturing files and operation parameters to the client-side command and control unit (27b) using the server (29a) and the internet interface (28).

[0079] The client-side command and control unit (27b) is configured to execute software for implementing other steps of the method for additively manufacturing an ophthalmic device, namely, the steps of laminating and curing the layers of the ophthalmic device to be manufactured.

[0080] In a modified example, the manufacturing system may be located on the supplier side, and the supplier-side command and control unit is configured to perform both determining the manufacturing file and operating parameters and additively manufacturing the ophthalmic device.

[0081] FIG. 3 is a block diagram illustrating the main steps of a method (100) for additively manufacturing an ophthalmic device (2) defined by an outer surface (10), and the method (100) is performed by a manufacturing system (1) as described above.

[0082] The method (100) includes the following steps.

[0083] - A step of determining and / or providing a manufacturing file including geometric characteristics of a so-called sliced ​​ophthalmic device (101);

[0084] - Step of laminating at least one first core layer by inkjet printing (102);

[0085] - Step of forming at least one second core layer on at least one first core layer at least partially by inkjet printing (103);

[0086] - Step (104) of inkjet printing at least one edge layer on at least one first core layer and adjacent to at least one second core layer.

[0087] The method (100) may further include the step of at least partially laminating at least one third core layer onto at least one second core layer by inkjet printing (105).

[0088] It should be noted that the step (104 and 105) of inkjet printing at least one edge layer and at least one third core layer can be performed at least partially simultaneously or at least partially continuously.

[0089] At least one first core layer may have at least one predetermined first thickness, at least one second core layer may have at least one predetermined second thickness that is the same as or different from the predetermined first thickness, at least one edge layer may partially define the outer surface (10) of the ophthalmic device (2) and may have at least one predetermined third thickness that is less than or equal to at least one predetermined second thickness, and at least one third core layer may have at least one predetermined fourth thickness that is the same as or different from at least one of the predetermined first thickness, the predetermined second thickness, and the predetermined third thickness.

[0090] The method (100) may further include at least one of the following steps.

[0091] - A step (106) of partially curing at least one first core layer before inkjet printing (103) at least one second core layer and before inkjet printing (104) at least one edge layer; and / or

[0092] - A step (107) of partially curing at least one second core layer before inkjet printing (104) at least one edge layer; and / or

[0093] - Step of partially curing at least one edge layer and / or at least one third core layer (108).

[0094] The method (100) may be repeatable. After the step (104 and / or 105) of inkjet printing at least one edge layer and / or at least one third core layer, the step (102 and / or 103) of inkjet printing additional first and second core layers to form layers and / or curing steps (106, 107 and 108) may follow.

[0095] The step (104) of inkjet printing at least one edge layer may include sub-steps of inkjet printing at least partially simultaneously and / or at least partially continuously several sub-edge layers of similar or different thicknesses arranged to be at least partially juxtaposed and / or at least partially overlapped to obtain at least one edge layer formed by a plurality of sub-edge layers.

[0096] Additionally, the step (102, 103, and 105) of inkjet printing at least one first core layer, at least one second core layer, and at least one third core layer may be performed with core print characteristics that are similar or different from each other, while the step (104) of inkjet printing at least one edge layer may be performed with edge print characteristics that are at least partially distinct from the core print characteristics.

[0097] Core print characteristics may be fixed or variable while inkjet printing at least one first, second, or third core layer, and edge print characteristics may be fixed or variable while inkjet printing at least one edge layer.

[0098] For example, the step of inkjet printing at least one first core layer, at least one second core layer, and also optionally a third core layer (102 and 103, and optionally 105) can be performed by at least one core print head among the plurality of inkjet print heads (6i), while the step of inkjet printing at least one edge layer (104) can be performed by at least one edge print head among the plurality of inkjet print heads (6i) separate from the core print head(s).

[0099] When the edge layer and the third core layer are inkjet printed simultaneously, this can be done, for example, by different inkjet print heads (6i) or by a single "hybrid" inkjet print head (6i) configured to provide both core print characteristics and edge print characteristics.

[0100] FIG. 4 illustrates a first example of a voxel distribution according to the method described above to obtain an ophthalmic device (2) having an outer surface (10) without stepped heights by inkjet printing multiple layers (3).

[0101] In particular, the "n-2" layer is inkjet printed here only as a core layer.

[0102] Next, the core layer (3a) of the "n-1" layer is partially inkjet printed on the "n-2" layer.

[0103] Next, the "n-2" and "n-1" layers are cured.

[0104] Subsequently, the "n" layer is simultaneously inkjet printed on the "n-1" layer as both the core layer (3a) and the edge layer (3b) around the core layer (3a).

[0105] Next, the "n" layer hardens.

[0106] Next, the edge layer (3b) of the "n-1" layer is inkjet printed partially on the "n-2" layer and around at least the core layer (3a) of the "n-1" layer.

[0107] The edge layer (3b) of the "n-1" layer has a closed ring shape here.

[0108] In FIG. 4, the “n” layer is obtained by a single image (In) containing, for example, two different voxel distributions (also called hybrid distributions) on the core and the edge, while the “n-1” layer is obtained by multiple images (In-1) in which, for example, one is core-only and the other is edge-only.

[0109] FIG. 5 illustrates two images having different voxel distributions, including an image (I1) showing randomly distributed core layers (3a) and edge layers (3b) and an image (I2) showing regularly distributed core layers (3a) and edge layers (3b).

[0110] FIG. 6 illustrates a second example of a voxel distribution according to the method described above, in which the edge layer (3b) is regularly distributed.

[0111] In particular, FIG. 6 focuses on sub-edge layers (3b) of similar or different thicknesses formed on the first core layer and around the second core layer (3a).

[0112] The sub-edge layers (3b) are divided into three zones, which are at least partially juxtaposed and at least partially overlapped according to the zones.

[0113] In this example, in the first zone, the largest droplets form sub-edge layers directly on the first core layer, in the second zone, the smallest droplets form sub-edge layers on the opposite side of the first core layer, and in the third zone, intermediate droplets form sub-edge layers located between the first zone and the second zone.

[0114] The sub-edge layers (3b) shown in FIG. 6 can be inkjet printed at least partially simultaneously and / or at least partially continuously by a single or multiple print heads (6i) and / or each other.

[0115] FIGS. 7 through 9 illustrate different images having different voxel distributions that can be used to perform the method according to the present disclosure and, in particular, the core layers (3a) and sub-edge layers (3b) illustrated in FIG. 6.

[0116] In FIG. 7, the first core layer (3a) is inkjet printed by an image (I0).

[0117] Next, the first sub-edge layer and the second core layer (3a) of the edge layer (3b) containing the largest droplets are simultaneously inkjet printed by the image (I1).

[0118] Next, the second sub-edge layer and the second core layer (3a) of the edge layer (3b) containing intermediate droplets are simultaneously inkjet printed by the image (I2).

[0119] Next, the second sub-edge layer and the second core layer (3a) of the edge layer (3b) containing the smallest droplets are simultaneously inkjet printed by the image (I3).

[0120] In the modified example of FIG. 8, the first core layer (3a) is inkjet printed by image (I0), and then the first sub-edge layer of the edge layer (3b) having the largest droplets and the second core layer (3a) are simultaneously inkjet printed by image (I1), and then the second sub-edge layer of the edge layer (3b) having the intermediate droplets is inkjet printed by image (I2), and then the second sub-edge layer of the edge layer (3b) having the smallest droplets is inkjet printed by image (I3).

[0121] In another variation of FIG. 9, the first core layer (3a) is inkjet printed by image (I0), then the second core layer (3a) is inkjet printed by image (I1), then the first sub-edge layer of the edge layer (3b) having the largest droplets is inkjet printed by image (I2), then the second sub-edge layer of the edge layer (3b) having medium droplets is inkjet printed by image (I3), and then the second sub-edge layer of the edge layer (3b) having the smallest droplets is inkjet printed by image (I4).

[0122] In these examples, curing steps can be performed between inkjet printing steps as described above.

[0123] FIG. 10 illustrates details of some images shown in FIG. 7 through 9 based on different droplet densities (A) and droplet volumes (B) for obtaining sub-edge layers of edge layer (3b), for example.

[0124] By the method according to the present disclosure, inkjet printing can be accurately controlled at a peripheral joint between two or more continuous layers, so that the outer surface of an ophthalmic device can be smoothed by at least one dedicated edge layer having a thickness less than or equal to the thickness of a layer formed around the edge layer and an optional layer formed around the edge layer.

[0125] In other words, the method according to the present disclosure enables the provision of an ophthalmic device having an outer surface as close as possible to a final outer surface, in which there is no stepped step or the stepped step is reduced on the outer surface of the ophthalmic device by means of 3D inkjet printing technology.

[0126] Additionally, the method according to the present disclosure enables discretizing the spacing between a plurality of thin sub-layers and slicing or dividing layers that would generally need to be thicker into these plurality of thin sub-layers in order to obtain a curvature as close as possible to the theoretical geometry, by depositing a precise small amount of material at least on the edge without any printing defects such as stepped steps that are actually “smoothed” and / or “self-flattened.”

[0127] It should be noted that the external surface to be obtained, and more generally the geometric characteristics of the ophthalmic device to be manufactured, may be adjusted according to the stepped step to be "smoothed" and / or "self-flattened," and may, for example, be slightly enlarged or extended.

[0128] In addition, since the edge layers described above can be determined by taking into account the "self-planarization" properties of the material itself, it is not necessary to completely fill the volume corresponding to the stepped step around each core layer, at least according to geometric properties and edge ink properties.

[0129] In variations,

[0130] - The support member may be a starting optical member, and the inkjet printer is configured to construct a complementary optical member formed by layers on the starting optical member;

[0131] - The support member may be part of a molding device, and layers may be constructed on the molding device to form a complementary optical member, and the complementary optical member is subsequently removed from the starting optical member and assembled with a separate standard blank;

[0132] - The support member may be part of a molding device, and layers may be built on the molding device to form a complementary optical member, and then a standard blank is formed, cast, or injection-molded directly within the molding device and onto the complementary optical member; and / or

[0133] - The support member may be part of the molding device, and layers may be built on the molding device to form a complementary optical member of a shape configured to be directly mounted on a pair of eyeglass frames.

[0134] More generally, it should be noted that the present disclosure is not limited to the examples described and expressed.

Claims

Claim 1 A method for additively manufacturing an ophthalmic device (2) defined by an outer surface (10), comprising the steps of: inkjet printing at least one first core layer (3a) having at least one predetermined first thickness; inkjet printing at least one second core layer (3a) having at least one predetermined second thickness that is equal to or different from the predetermined first thickness at least partially on the at least one first core layer (3a) (103); and inkjet printing at least one edge layer (3b) on the at least one first core layer (3a) and adjacent to the at least one second core layer (3a) (104), wherein the at least one edge layer has at least one predetermined third thickness that is less than or equal to the at least one predetermined second thickness and at least partially defines the outer surface (10) of the ophthalmic device (2). Claim 2 A method according to claim 1, comprising the step (106, 107) of at least partially curing the at least one first core layer (3a) and / or the at least one second core layer (3a) before inkjet printing (104) the at least one edge layer (3b). Claim 3 A method according to claim 1 or 2, comprising the step (105) of at least partially inkjet printing on at least one second core layer (3a) at least partially inkjet printing at least one third core layer (3a) having at least one predetermined fourth thickness that is the same as or different from at least one of the predetermined first thickness, the predetermined second thickness, and the predetermined third thickness, and the step (106) of at least partially simultaneously or at least partially continuously inkjet printing the at least one edge layer with inkjet printing (105) of the at least one third core layer. Claim 4 A method according to any one of claims 1 to 3, wherein the at least one edge layer (3b) comprises several sub-edge layers of similar or different thicknesses, and the sub-edge layers are at least partially juxtaposed and / or at least partially overlapped. Claim 5 A method according to claim 4, wherein the sub-edge layers are inkjet printed at least partially simultaneously and / or at least partially continuously with respect to each other. Claim 6 A method according to any one of claims 1 to 5, wherein the at least one edge layer (3b) has a closed loop shape around the at least one second core layer. Claim 7 A method according to any one of claims 1 to 6, wherein the step (102, 103) of inkjet printing the at least one first core layer (3a) and the at least one second core layer (3a) is performed with fixed or variable core print characteristics while inkjet printing the at least one first core layer and the at least one second core layer, while the step (104) of inkjet printing the at least one edge layer is at least partially separate from the core print characteristics and is performed with fixed or variable edge print characteristics while inkjet printing the at least one edge layer. Claim 8 A method according to claim 7, wherein each of the core print characteristics and the edge print characteristics comprises a core ink material and / or core droplet density and / or core droplet volume and / or core droplet viscosity and / or core droplet ejection rate, and each of the edge ink material and / or edge droplet density and / or edge droplet volume and / or edge droplet viscosity and / or edge droplet ejection rate. Claim 9 A method according to any one of claims 1 to 8, wherein the step (102, 103) of inkjet printing the at least one first core layer (3a) and the at least one second core layer (3a) is performed by a core print head, while the step of inkjet printing the at least one edge layer (3b) is performed by an edge print head separate from the core print head. Claim 10 A method comprising the step (101) of determining a manufacturing file including geometric characteristics of a sliced ​​ophthalmic device, wherein, in any one of claims 1 to 9, at least a first core layer (3a), a second core layer (3a), and at least one edge layer (3b) forming an outer surface (10) of the ophthalmic device (2) at a peripheral joint between the first core layer and the second core layer. Claim 11 In claim 10, the manufacturing file comprises parameters defined by a plurality of images (I0, I1, I2, I3, I4) each representing a voxel distribution or droplet distribution used to activate and deactivate nozzles (8) of print head(s) (6i) to perform inkjet printing, wherein the images are determined by at least one mathematical function such as a linear, power, polynomial, exponential, logarithmic, sine curve, etc., used alone or in combination. Claim 12 A command and control unit comprising system elements configured to execute a computer program for additive manufacturing of an ophthalmic device (2) defined by an outer surface (10) by implementing the steps of: inkjet printing at least one first core layer (3a) having at least one predetermined first thickness; inkjet printing at least one second core layer (3a) having at least one predetermined second thickness that is equal to or different from the predetermined first thickness (103); and inkjet printing at least one edge layer (3b) on the at least one first core layer and adjacent to the at least one second core layer (104), wherein the at least one edge layer defines at least partially the outer surface of the ophthalmic device and has at least one predetermined third thickness that is less than or equal to the at least one predetermined second thickness. Claim 13 A manufacturing system comprising an inkjet printer (4) comprising at least one inkjet print head (6i) having a plurality of nozzles (8) and a command and control unit (7), wherein the system is configured to additively manufacture an ophthalmic device (2) defined by an outer surface (10) by the steps of: inkjet printing at least one first core layer (3a) having at least one predetermined first thickness; inkjet printing at least one second core layer (3a) having at least one predetermined second thickness that is equal to or different from the predetermined first thickness at least partially on the at least one first core layer (103); and inkjet printing at least one edge layer (3b) on the at least one first core layer and adjacent to the at least one second core layer (104), wherein the at least one edge layer defines at least partially the outer surface of the ophthalmic device and has at least one predetermined third thickness that is less than or equal to the at least one predetermined second thickness. Manufacturing system. Claim 14 A computer program configured to additively manufacture an ophthalmic device (2) defined by an outer surface (10) by implementing, when the computer program is executed by a computer, the steps of: inkjet printing at least one first core layer (3a) having at least one predetermined first thickness; inkjet printing at least one second core layer (3a) having at least one predetermined second thickness that is equal to or different from the predetermined first thickness (103); and inkjet printing at least one edge layer (3b) on the at least one first core layer and adjacent to the at least one second core layer (104), wherein the at least one edge layer defines at least partially the outer surface of the ophthalmic device and has at least one predetermined third thickness that is less than or equal to the at least one predetermined second thickness. Claim 15 As a client-server communication interface, the client-server communication interface transmits to a remote computer at least manufacturing data for additive manufacturing of an ophthalmic device (2) defined by an outer surface (10), such as a manufacturing file including geometric characteristics of a sliced ​​ophthalmic device, such as at least one first core layer (3a), at least one second core layer (3a), and at least one edge layer (3b), which form the outer surface of the ophthalmic device at a peripheral junction between at least one first core layer and at least one second core layer, determined by the computer program when the computer program is executed in a command and control unit; and the remote computer performs the steps of: inkjet printing at least one first core layer having at least one predetermined first thickness (102); at least one second core layer having at least one predetermined second thickness that is the same as or different from the predetermined first thickness, at least partially inkjet printing on the at least one first core layer (103); and on the at least one first core layer and on the at least one second core layer A client-server communication interface configured to implement the step (104) of inkjet printing at least one edge layer adjacently, wherein the at least one edge layer partially defines the outer surface of the ophthalmic device and has at least one predetermined third thickness less than or equal to the at least one predetermined second thickness.

Images