Additive Ophthalmic Device Build Angle for Diffracted Ray Control
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Solution Overview
Problem
Additive manufacturing of ophthalmic devices often results in optical defects due to refractive index inhomogeneity at the junction of layers, leading to vision distortions caused by diffracted rays that can hinder the wearer's vision.
Innovation Solution
The method involves determining a build inclination angle to direct diffracted rays of light outside the retina's useful vision zones by adjusting the orientation of the ophthalmic device during layer formation, ensuring these rays do not impact the wearer's vision by redirecting them to a dedicated zone outside the main vision area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is performed with standard layering orientation, then manufacturing simplicity is maintained, but optical defects occur due to diffracted rays reaching the retina
Solution Approach 1:
The patent applies asymmetry by determining a specific build inclination angle that creates an asymmetric orientation of layers relative to the optical axis. This asymmetric configuration redirects diffracted rays away from the retina's useful vision zones, resolving the contradiction between manufacturing simplicity and avoiding vision distortion.
Solution Approach 2:
The patent changes the parameter of build inclination angle from the conventional vertical orientation to a specific inclined angle. This parameter modification alters the path of diffracted rays without fundamentally changing the additive manufacturing process, thus maintaining ease of manufacture while eliminating vision distortion.
2Manufacturing precision
If build inclination angle is adjusted to redirect diffracted rays, then vision quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies a single parameter (build inclination angle) rather than fundamentally changing the manufacturing process. This approach improves optical quality by redirecting diffracted rays while minimizing the increase in manufacturing complexity, as the change can be implemented through software control of existing additive manufacturing equipment.
Solution Approach 2:
The build inclination angle is determined in advance during the design and planning phase, before the actual additive manufacturing process begins. This preliminary determination of the optimal angle allows the manufacturing process to proceed systematically without requiring complex real-time adjustments, thus improving vision quality while limiting the increase in manufacturing complexity.
3Productivity
If layers are built vertically along the optical axis, then manufacturing process is straightforward, but diffracted rays directly reach the retina causing vision distortion
Solution Approach 1:
The patent introduces asymmetry by inclining the layer building direction relative to the optical axis. This asymmetric configuration changes the diffraction pattern such that diffracted rays are redirected away from the retina's useful vision zones, resolving the contradiction between straightforward manufacturing and avoiding vision distortion.
Solution Approach 2:
The patent changes the build orientation parameter from vertical (parallel to optical axis) to an inclined angle. This parameter modification maintains manufacturing efficiency by using a systematic layering approach while fundamentally altering the light diffraction behavior to prevent vision distortion.
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 mitigates optical defects and vision distortions by redirecting disturbing diffracted rays away from the retina, maintaining clear vision for the wearer without deleting the defects but rather hiding them from the wearer's perception.
Implementation Method 1
additive manufacturing of ophthalmic devices often results in optical defects due to refractive index inhomogeneity at the junction of layers, leading to vision distortions caused by diffracted rays
Implementation Method 2
determining a build inclination angle so that to direct disturbing diffracted rays of a beam of light on a dedicated zone located outside at least a zone of a retina
Data Source
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AI summary
The disclosure provides a method for additively manufacturing an ophthalmic device (2) to be worn by a wearer (60), the method comprising: additively manufacturing a plurality of layers (3) of a predetermined material in order to obtain the ophthalmic device, and determining a build inclination angle so that to direct diffracted rays (70) of a beam of light (71) on a dedicated zone located outside a zone of a retina of an eye of the wearer useful for vision when the ophthalmic device is worn by the wearer.