Additive Fabricated Ophthalmic Device Surface Roughness Control
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Solution Overview
Problem
Existing additive fabrication techniques are unable to achieve the necessary surface roughness of less than 10 microns, and typically greater than 50 microns, which is required for ophthalmic devices to ensure accurate refractive indices.
Innovation Solution
The development of an ophthalmic device with an optical surface formed by additive fabrication, where the surface roughness is achieved by depositing and synergistically stimulating particulates with sizes less than 10 microns, and in select configurations less than 2 microns and certain configurations less than one micron, to form solidified layers with precise topography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive fabrication techniques are used, then manufacturing capability is achieved, but surface roughness exceeds 50 microns which is insufficient for ophthalmic devices
Solution Approach 1:
The patent changes the particle size parameter from conventional larger particles to particles smaller than 10 microns, and in select configurations smaller than 2 microns and certain configurations smaller than one micron. This parameter change enables the additive fabrication process to achieve surface roughness of less than 10 microns, and in select configurations less than 2 microns and certain configurations less than one micron, which is sufficient for ophthalmic devices while maintaining manufacturing capability
Solution Approach 2:
The patent segments the optical surface into multiple solidified layers, each formed by depositing and synergistically stimulating particulates. By controlling the particle size and layer formation process, the segmentation approach enables precise control over surface roughness at the micron level, achieving the required optical surface quality while maintaining manufacturing feasibility
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 allows for the creation of ophthalmic devices with optical surfaces that have a surface roughness of less than 10 microns, and in select configurations less than 2 microns and certain configurations less than one micron, thereby minimizing discrepancies in refractive indices and improving the optical performance of the devices.
Implementation Method 1
synergistically stimulating the first lamina of particulates to form a first solidified layer
Data Source
AI summary
An ophthalmic device is formed by additive fabrication, the optical device having an optical surface with a surface roughness on the order of less than 10 microns. A method is provided for making an ophthalmic device including an optical surface having a surface roughness of less than 10 microns by depositing on a stage in a first relative position a first lamina of particulates having a size less than 10 microns and in select configurations less than two microns and certain configurations less than one micron, and, synergistically stimulating the first lamina of particulates to form a first solidified layer.