Additive Manufacturing Bespoke Eyewear via Facial Scanning
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Solution Overview
Problem
Existing methods for manufacturing bespoke eyewear require manual or automatic assembly of multiple pieces, which is inefficient and lacks precision, despite advancements in additive manufacturing and optical scanning for facial measurements.
Innovation Solution
A system and method that captures facial images to generate three-dimensional digital models of eyewear frames, aligning lens bases with specific parameters to create seamless hinge structures, allowing for additive manufacturing without manual assembly, using facial parameters like Nasal Crest and Pupil Center, and lens parameters like Geometric Center, Wrap Angle, and Pantoscopic Angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional additive manufacturing is used to produce customized eyewear, then facial measurement precision is improved through optical scanning, but assembly complexity increases requiring manual or robotic assembly of multiple pieces
Solution Approach 1:
The patent merges multiple separate eyewear components (front frame, temple arms, hinges, nose pads) into a single integrated structure that is additively manufactured as one continuous piece. This eliminates the need for manual or robotic assembly of multiple pieces while maintaining the benefits of optical scanning for precise facial measurements. The seamless integration resolves the contradiction by combining high-precision measurement capabilities with simplified single-piece manufacturing.
2Adaptability or versatility
If eyewear frames are produced in separate pieces for customization, then adaptability to different facial parameters is improved, but manufacturing time increases due to assembly requirements
Solution Approach 1:
The patent incorporates all customization features and structural elements directly into the digital 3D model before additive manufacturing. Facial parameters, lens alignments, hinge mechanisms, and aesthetic variations are all pre-integrated into the seamless frame design, eliminating the need for post-manufacturing assembly operations. This preliminary integration of all customization aspects into a single manufacturable model resolves the contradiction by maintaining full adaptability while dramatically reducing manufacturing time.
3Manufacturing precision
If manual assembly of eyewear components is performed, then adjustment precision for individual fit is improved, but labor intensity and production cost increase
Solution Approach 1:
The patent replaces the mechanical assembly process with an additive manufacturing process that directly creates the final fitted eyewear frame in one operation. The system uses digital facial scanning and 3D modeling to achieve precise fit customization, then additively manufactures the complete frame including integrated hinges and nose pads without requiring manual assembly. This substitution of additive manufacturing for mechanical assembly resolves the contradiction by maintaining precision through digital modeling while dramatically improving productivity.
Data Source
AI summary
The present disclosure provides a bespoke eyewear and a system and a method for manufacturing the bespoke eyewear. In one aspect, the method for manufacturing the bespoke eyewear frame includes capturing one or more facial images of a user using an image capturing device, generating a facial model from said one or more facial images, extracting a plurality of facial parameters from the facial model, generating a three-dimensional digital model of an eyewear frame based at least in part on one or more of the facial parameters of the user, and transmitting the three-dimensional digital model to an additive manufacturing apparatus for additively manufacturing the bespoke eyewear frame.