Laser Ablation for Custom Soft Contact Lens Design
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Solution Overview
Problem
Conventional cast molding processes for soft contact lenses limit design variations and require large batches due to high tooling costs, making it economically impractical to produce custom lens designs for individual patients, especially for specific needs like correcting high-order aberrations or improving performance during activities.
Innovation Solution
The process involves forming a contact lens via cast molding and then using a laser to ablate specific portions of the lens, modifying its refractive characteristics or design, such as using an excimer laser to alter the lens material's molecular bonds and shape according to individual patient metrics and needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cast molding is used to manufacture contact lenses, then manufacturing efficiency and consistency are improved, but design flexibility and customization capability deteriorate
Solution Approach 1:
The manufacturing process is divided into two independent stages: (1) mass production of standard lenses using cast molding for high efficiency, and (2) post-manufacturing customization using laser ablation for design flexibility. This segmentation allows each stage to optimize for its specific function without compromise.
Solution Approach 2:
Standard lens designs are pre-manufactured using cast molding to establish a base product. Customization is then achieved through selective material removal via laser ablation, allowing rapid adaptation without retooling the entire manufacturing process.
2Manufacturing precision
If custom lens designs are produced for individual patients, then visual acuity and comfort are improved, but manufacturing cost increases
Solution Approach 1:
Only the specific portions of lens material needed for customization are removed through laser ablation, rather than manufacturing entirely custom lenses from scratch. This selective extraction minimizes material waste and reduces manufacturing complexity.
Solution Approach 2:
The laser ablation process enables precise control over material removal depth and pattern, allowing customization of lens parameters such as refractive index distribution, surface curvature, and thickness profile to match individual patient requirements while maintaining cost efficiency.
3Manufacturing precision
If laser ablation is used to modify lenses, then customization precision is improved, but processing time increases
Solution Approach 1:
The laser ablation process uses pulsed laser delivery rather than continuous irradiation, allowing controlled material removal with cooling intervals between pulses. This periodic action prevents excessive heat buildup and enables precise customization without excessive processing time.
Solution Approach 2:
Traditional mechanical machining methods are replaced with laser-based ablation, which removes material through photothermal or photomechanical effects rather than mechanical contact. This substitution enables higher precision with reduced tool wear and faster processing speeds.
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 method allows for customized lens modifications that can correct high-order aberrations and enhance performance for specific activities, such as flying or reading, by precisely altering the lens's shape and refractive properties, improving comfort and visual acuity.
Implementation Method 1
controllably irradiated with a laser beam to ablate portions of the lens and thereby modify the lens
Implementation Method 2
irradiated with a laser thereby modifying at least one characteristic of the ophthalmic lens. In some embodiments, a portion of the ophthalmic lens is ablated
Data Source
AI summary
This invention discloses methods and apparatus for modifying a silicone contact lens via laser ablation and a resulting modified lens. In some embodiments a lens is ablated in a hydrated state. A lens may also be ablated in an environment of decreased oxygen content.