Femtosecond Laser IOL Fabrication with Refractive Index Shaping
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Solution Overview
Problem
Current methods for manufacturing intraocular lenses (IOLs) are limited by their inability to provide fully corrective lenses with linear diopter ranges, fail to account for temperature differences, and do not adequately correct for toricity, asphericity, multifocality, and higher order optical aberrations (HOAs).
Innovation Solution
A pulsed laser system is used to fabricate intraocular lenses from a polymeric material blank, employing a high-repetition rate femtosecond laser with a short pulse length to create customized lenses with Refractive Index Shaping (RIS) inside the IOL, allowing for precise sculpting and modification of optical properties to correct for various vision irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molding technique is used to manufacture IOLs, then production efficiency is improved, but manufacturing precision and customization capability deteriorate
Solution Approach 1:
The patent replaces traditional mechanical molding and lathing systems with a femtosecond laser-based fabrication system. The laser enables precise material removal and refractive index modification through photodisruption and optical heating, achieving customization precision while maintaining automated production efficiency. The laser system can be numerically controlled to create any lens geometry without physical molds.
Solution Approach 2:
The patent utilizes the ability to change laser parameters (pulse duration, repetition rate, wavelength, focal position) to achieve different manufacturing outcomes. By adjusting these parameters, the system can perform both material ablation for shape creation and refractive index modification for optical property customization, resolving the contradiction between efficiency and precision.
2Manufacturing precision
If lathing and milling at reduced temperature is used, then manufacturing precision is improved, but reliability deteriorates due to temperature-induced optical property changes
Solution Approach 1:
The patent replaces mechanical lathing and milling with laser-based fabrication that operates at or near physiological temperature. The femtosecond laser delivers such brief pulses that minimal heat diffusion occurs, and the process can be conducted in aqueous environments mimicking physiological conditions, eliminating temperature-induced optical property changes while maintaining manufacturing precision.
Solution Approach 2:
The patent exploits the phase transition characteristics of femtosecond laser pulses in polymeric materials. The ultra-short pulse duration causes localized photodisruption and plasma formation without significant thermal diffusion, allowing precise material removal and refractive index modification while maintaining the material in its physiological state, thus ensuring optical performance consistency.
3Device complexity
If discrete steps of diopter power are used in molding, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent transitions from static, discrete diopter steps in molded lenses to dynamic, continuous diopter adjustment capability. The laser system can modify refractive index and lens geometry continuously during fabrication, allowing customization to any diopter value within the material's range rather than being limited to predetermined discrete steps.
Solution Approach 2:
The patent applies local quality by enabling different regions of the lens to have different refractive indices and optical properties. The laser can selectively modify specific zones of the polymeric material to create multifocal, aspheric, or toric corrections tailored to the patient's specific visual needs, achieving high precision without increasing overall device complexity.
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
This approach enables the production of lenses that provide precise correction for sphere, cylinder, asphericity, multifocality, and HOAs, improving vision by allowing for per-patient customization and maintaining optical performance across temperature changes.
Implementation Method 1
A pulsed laser system is used to fabricate intraocular lenses from a polymeric material blank, employing a high-repetition rate femtosecond laser with a short pulse length to create customized lenses with Refractive Index Shaping (RIS) inside the IOL
Implementation Method 2
A pulsed laser system is used to fabricate intraocular lenses from a polymeric material blank, employing a high-repetition rate femtosecond laser with a short pulse length to create customized lenses with Refractive Index Shaping (RIS) inside the IOL
Implementation Method 3
A pulsed laser system is used to fabricate intraocular lenses from a polymeric material blank, employing a high-repetition rate femtosecond laser with a short pulse length to create customized lenses
Data Source
AI summary
A system/method allowing intraocular lens (IOL) fabrication using a femtosecond laser is disclosed. The system and method generate a stream of pulses at a rate of at least 1 million pulses per second and a pulse length of 300 femtoseconds or less to sculpt a polymeric material blank (PMB) to form an IOL. The high repetition rate and short pulse length combine to permit IOL fabrication in less than 10 minutes. During this fabrication procedure a lens may be formed within the IOL by incorporating a refractive index shaping (RIS) structure within the IOL. Additionally, IOL haptics may be formed during this IOL formation process. This combination of physical feature generation and RIS structure generation permits per-patient customization of the IOL as it relates to sphere, cylinder, asphericity, multifocality, and/or higher optical aberrations (HOAs).