Abrasive-Filled Fluid Jet Manufacturing for Micro-Lens Precision
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Solution Overview
Problem
Existing methods for manufacturing complex ophthalmic lenses, such as those with micro-lenses, fail to provide satisfactory results, especially when there is a need for specific adaptation to a wearer's eye or for small volumes.
Innovation Solution
A method using an abrasive-filled fluid jet for manufacturing lens elements, which includes steps such as microstructuring and polishing using a mold or master piece, and employing a nozzle system with different nozzles for coarse and fine treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional thermoforming or additive manufacturing methods are used to manufacture complex ophthalmic lenses with micro-lenses, then the manufacturing process can be implemented, but the manufacturing precision and quality of the optical elements are not satisfactory
Solution Approach 1:
The patent replaces traditional mechanical machining methods with abrasive-filled fluid jet technology. The fluid jet delivers abrasive particles at high velocity to erode and shape the mold surfaces and lens elements, achieving micro-scale precision without mechanical contact. This substitution enables precise manufacturing of complex micro-lens structures while avoiding the limitations of conventional mechanical tools.
Solution Approach 2:
The patent utilizes controllable parameters of the fluid jet system including particle size distribution, jet pressure, flow rate, and standoff distance to achieve different machining effects. By adjusting these parameters, the system can transition between roughing and finishing operations, enabling precise control over the geometry and surface quality of optical elements.
2Adaptability or versatility
If conventional manufacturing methods are used, then production can be performed, but adaptability to individual wearer's eye and customization capability are limited
Solution Approach 1:
The patent employs master molds that are pre-designed with specific optical prescriptions and micro-lens patterns. These master molds can be used repeatedly to manufacture multiple customized lenses, combining the benefits of customization with efficient production. The fluid jet technology enables rapid fabrication of these master molds, making the customization process practical for production environments.
3Manufacturing precision
If traditional machining methods are used for mold preparation, then molds can be manufactured, but the surface finish quality and micro-structure precision are insufficient
Solution Approach 1:
The patent replaces time-consuming manual and mechanical polishing processes with abrasive-filled fluid jet finishing. The fluid jet delivers controlled erosion and surface refinement in a single automated process, achieving optical-quality surface finishes on mold surfaces and lens elements without the sequential operations required by traditional methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves precise and efficient manufacturing of ophthalmic lenses with microstructures, allowing for personalized adaptation and high-volume production, while improving manufacturing processes.
Implementation Method 1
a step of using an abrasive-filled fluid jet to manufacture the lens element
Implementation Method 2
The abrasive-filled fluid jet is for example maintained perpendicular to the surface to be machined
Data Source
AI summary
This relates to a method for manufacturing a lens element including: a refraction area having first curvature; a plurality of optical elements located on at least part of the refraction area, wherein the method includes a step of using an abrasive-filled fluid jet to manufacture the lens element.