Voxel-Based Lithography for Custom Ophthalmic Lens Precursors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing ophthalmic lenses, such as cast molding, struggle to produce customized lenses tailored to specific patients or applications, as they are limited by the nature of injection molding processes and equipment, which are not conducive to forming custom shapes or sizes effectively.
Innovation Solution
A Voxel-based lithographic apparatus is used to create a Lens Precursor by exposing a Reactive Mixture to actinic radiation, allowing for controlled curing and shaping of ophthalmic lenses with customizable optical and non-optical characteristics, including the use of a digital micromirror device for precise light modulation and environmental controls for optimal lens formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cast molding with injection molding processes is used to manufacture ophthalmic lenses, then high volume production of standard lens sizes and powers is achieved, but customization capability for specific patient eyes is lost
Solution Approach 1:
The invention segments the lens manufacturing process into two distinct stages: (1) creating a customizable lens precursor with the desired unique shape and optical properties using photolithography, and (2) molding the precursor into the final lens form. This segmentation allows customization in the precursor creation stage while maintaining efficient molding processes in the second stage, thereby resolving the contradiction between high-volume production and customization capability.
Solution Approach 2:
The invention performs preliminary action by creating a lens precursor that contains the unique custom shape and optical characteristics before the actual lens molding process. The precursor is formed using photolithography techniques that allow precise customization for each patient's eye, and then this pre-formed precursor is used in subsequent molding operations, enabling both customization and efficient production.
2Ease of manufacture
If traditional molding techniques are used, then manufacturing efficiency is maintained, but the ability to form custom shapes and sizes is limited
Solution Approach 1:
The invention replaces traditional mechanical molding techniques for shape formation with photolithography methods. Instead of using mechanical molds to force the lens material into shape, the invention uses light-based photolithography to precisely define the lens precursor shape according to the patient's unique eye geometry, thereby achieving high manufacturing precision for custom shapes while maintaining overall manufacturing efficiency through automated optical processes.
3Adaptability or versatility
If custom lenses are formed using lathing or stereo lithography, then patient-specific customization is achieved, but production time increases and material limitations arise
Solution Approach 1:
The invention changes the material parameter by using a lens precursor formulation that can be precisely controlled during photolithography. This formulation allows the material to be shaped with high precision while maintaining properties suitable for final lens performance. The precursor approach enables faster production compared to traditional lathing or stereo lithography because the photolithography process can be optimized for speed while still achieving the required customization, thereby reducing production time while maintaining patient-specific capabilities.
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
The method enables the production of high-quality, customizable ophthalmic lenses with varied optical performance and material properties, such as hydrogel or silicone hydrogel lenses, that can be tailored to individual specifications, overcoming the limitations of traditional manufacturing techniques.
Implementation Method 1
The actinic radiation is controllable to cure a portion of the Reactive Mixture in a predefined pattern
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An ophthalmic lens precursor comprising a lens precursor Form; and a fluent lens reactive mixture wherein the lens precursor form is a solid component having a first optical surface and a second surface defined by the operation of a voxel-based lithographic system, and wherein the fluent lens reactive mixture is adhered to the second surface of the lens precursor form.