Method and system to create custom, user-specific eyewear

• US 9,529,213 B2
• Filed: 04/03/2015
• Issued: 12/27/2016
• Est. Priority Date: 08/22/2013
• Status: Active Grant

• Current Assignee: Bespoke Inc.
• Original Assignee: Bespoke Inc.
• Inventors: Fonte, Timothy A., Varady, Eric J.
• Primary Examiner(s): Kim, Eunhee
• Application Number:
  US14/678,219
• Publication Number:
  US 20150212343A1
• Time in Patent Office: 634 Days
• Field of Search: 703/1, 703/2, 700/98, 351/178, 351/159.75
• US Class Current: 1/1
• CPC Class Codes: A61B 3/0041 characterised by display arrangements
• CPC Class Codes: A61B 3/111 for measuring interpupillary distance
• CPC Class Codes: B29D 12/02 Spectacle frames constructional form G02C
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G02C 13/001 Assembling; Repairing
• CPC Class Codes: G02C 13/003 Measuring during assembly or fitting of spectacles
• CPC Class Codes: G02C 13/005 Measuring geometric parameters required to locate ophtalmic lenses in spectacles frames apparatus for testing or instruments for examining the eyes per se A61B3/00; machines or devices and accessories for grinding the edges of lenses using spectacles as a template B24B9/144
• CPC Class Codes: G02C 7/024 Methods of designing ophthalmic lenses
• CPC Class Codes: G02C 7/027 considering wearer's parameters
• CPC Class Codes: G06F 16/22 Indexing; Data structures therefor; Storage structures
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: G06Q 30/0621 Item configuration or customization
• CPC Class Codes: G06T 19/20 Editing of 3D images, e.g. changing shapes or colours, aligning objects or positioning parts
• CPC Class Codes: G06T 2219/2012 Colour editing, changing, or manipulating; Use of colour codes
• CPC Class Codes: G06V 40/166 using acquisition arrangements
• CPC Class Codes: G06V 40/169 Holistic features and representations, i.e. based on the facial image taken as a whole
• CPC Class Codes: G16B 5/00 ICT specially adapted for modelling or simulations in systems biology, e.g. gene-regulatory networks, protein interaction networks or metabolic networks
• CPC Class Codes: G16H 50/50 for simulation or modelling of medical disorders
• CPC Class Codes: H04L 65/403 : Arrangements for multi-party communication, e.g. for conferences data switching systems for conference H04L12/18; arrangements for connecting several subscribers to a common circuit, i.e. affording conference facilities H04M3/56; television conferencing systems H04N7/15
• CPC Class Codes: H04N 23/611 : where the recognised objects include parts of the human body

Abstract

Systems and methods for creating fully custom products from scratch without exclusive use of off-the-shelf or pre-specified components. A system for creating custom products includes an image capture device for capturing image data and/or measurement data of a user. A computer is communicatively coupled with the image capture device and configured to construct an anatomic model of the user based on the captured image data and/or measurement data. The computer provides a configurable product model and enables preview and automatic or user-guided customization of the product model. A display is communicatively coupled with the computer and displays the custom product model superimposed on the anatomic model or image data of the user. The computer is further configured to provide the customized product model to a manufacturer for manufacturing eyewear for the user in accordance with the customized product model. The manufacturing system is configured to interpret the product model and prepare instructions and control equipment for the manufacturing of the customized product.

Claims

1. A computer-implemented method for generating instructions for manufacturing an individual-specific eyewear product, using a computer system, the method comprising:

quantifying at least a portion of an anatomic feature of an individual;

generating a configurable parametric model of an individual-specific eyewear product for the individual, by shaping a surface or a contour of the configurable parametric model to match the quantified portion of the anatomic feature of the individual;

receiving a request for modifying one or more geometric parameters of the configurable parametric model;

generating an updated parametric model of the individual-specific eyewear product for the individual, based on the received request for modifying the one or more geometric parameters of the configurable parametric model; and

generating an electronic file comprising instructions for manufacturing a physical embodiment of the individual-specific eyewear product according to the updated parametric model.

2. The method of claim 1, further comprising:

converting the updated parametric model, instructions, or electronic file into one or more computer numerical control codes, flat patterns, rapid prototyping instructions, instructions for additive manufacturing methods, or robotic control instructions.

3. The method of claim 1, further comprising:

determining one or more manufacturing metrics associated with manufacturing the physical embodiment of the individual-specific eyewear product, wherein the one or more manufacturing metrics include a selection of one or more raw materials, production capacities, schedules, product specifications, or quality checks.

4. The method of claim 1, further comprising:

generating one or more templates, one or more criteria, or one or more three-dimensional models including at least one of the one or more geometric features of the individual'"'"'s anatomy for quality control in manufacturing the physical embodiment of the individual-specific eyewear product.

5. The method of claim 1, wherein the instructions for manufacturing the individual-specific eyewear product according to the updated parametric model include one or more specifications, data structures, computer-numerical-control instructions, machine-readable instructions, technician instructions, or model files interpretable by manufacturing systems.

6. The method of claim 1, further comprising:

determining a method of manufacturing the physical embodiment of the individual-specific eyewear product according to the updated parametric model; and

modifying the generation of the electronic file comprising instructions for manufacturing the physical embodiment of the individual-specific eyewear product based on the determined method of manufacture.

7. The method of claim 1, further comprising:

generating the instructions for manufacturing the physical embodiment of the individual-specific eyewear product, including instructions for automated or human inspection for quality control.

8. The method of claim 1, further comprising:

identifying a subdivision of the updated parametric model as a part for a flat pattern; and

generating the instructions for manufacturing the individual-specific eyewear product based on instructions for manufacturing one or more flat patterns for the identified subdivision of the updated parametric model.

9. The method of claim 1, further comprising:

determining a manipulation to perform on a subdivision of the updated parametric model;

determining geometric information associated with the manipulation to perform on the subdivision of the updated parametric model; and

generating the instructions for manufacturing the individual-specific eyewear product based on the geometric information associated with the manipulation to perform on the subdivision of the updated parametric model.

10. The method of claim 9, wherein the manipulation includes bending, folding, or forming performed by automated equipment on the geometric information for the manipulation of the subdivision of the updated parametric model.

11. The method of claim 1, wherein the updated parametric model includes prescription information, lens information, user information associated with the individual, lens laser-marking, lens edge machining instructions, parameters entered by the individual or by a different user, or design attribute information.

12. The method of claim 11, wherein the design attribute information includes one or more surfaces, polishes, marks, coats, edge lenses, logos, decorative markings, colors, patterns, or materials.

13. The method of claim 1, further comprising:

determining one or more stages for manufacturing the individual-specific eyewear product according to the updated parametric model; and

generating a sequence of commands for at least one of the one or more stages of manufacturing the individual-specific eyewear product according to the updated parametric model, wherein the electronic file includes the sequence of commands.

14. The method of claim 1, further comprising:

determining one or more manufacturing metrics for the manufacturing of the individual-specific eyewear product according to the updated parametric model; and

generating the electronic file for generating instructions for the manufacturing of the individual-specific eyewear product based on an optimization of the one or more manufacturing metrics.

15. The method of claim 1, further comprising:

determining a prediction associated with the manufacturing of the individual-specific eyewear product according to the updated parametric model, wherein the prediction is based on a time for completing the manufacturing of the individual-specific eyewear product or an expected shipping date for completing the manufacturing of the individual-specific eyewear product.

16. The method of claim 1, further comprising:

determining a time for completing the manufacturing of the individual-specific eyewear product according to the updated parametric model or determining an expected shipping date for completing the manufacturing of the individual-specific eyewear product according to the updated parametric model.

17. The method of claim 1, further comprising:

determining a price for manufacturing the individual-specific eyewear product according to the updated parametric model.

18. The method of claim 1, wherein the individual-specific product includes an eyewear frame.

19. A computer system for generating instructions for manufacturing an individual-specific eyewear product, the system comprising:

a data storage device storing instructions for generating instructions for manufacturing an individual-specific eyewear product; and

a processor configured to execute the instructions to perform a method comprising;

quantifying at least a portion of an anatomic feature of an individual;

generating a configurable parametric model of an individual-specific eyewear product for the individual, by shaping a surface or a contour of the configurable parametric model to match the quantified portion of the anatomic feature of the individual;

receiving a request for modifying one or more geometric parameters of the configurable parametric model;

generating an updated parametric model of the individual-specific eyewear product for the individual, based on the received request for modifying the one or more geometric parameters of the configurable parametric model; and

generating an electronic file comprising instructions for manufacturing a physical embodiment of the individual-specific eyewear product according to the updated parametric model.

20. A non-transitory computer readable medium for use on a computer system containing computer-executable programming instructions for generating instructions for manufacturing an individual-specific eyewear product according to a method comprising:

quantifying at least a portion of an anatomic feature of an individual;

generating a configurable parametric model of an individual-specific eyewear product for an individual, by shaping a surface or a contour of the configurable parametric model to match the quantified portion of the anatomic feature of the individual;

receiving a request for modifying one or more geometric parameters of the configurable parametric model;

generating an updated parametric model of the individual-specific eyewear product for the individual, based on the received request for modifying the one or more geometric parameters of the configurable parametric model; and

generating an electronic file comprising instructions for manufacturing a physical embodiment of the individual-specific eyewear product according to the updated parametric model.

21. A computer-implemented method for generating instructions for generating a model of an individual-specific eyewear product, using a computer system, the method comprising:

receiving an anatomic model of an individual'"'"'s face;

identifying and quantifying one or more geometric features of the anatomic model of the individual'"'"'s face;

determining one or more optical measurements for lens construction based on the one or more identified and quantified geometric features of the anatomic model; and

determining a configurable parametric model of an individual-specific eyewear product for an individual by generating one or more surfaces of a lens portion of the configurable parametric model based on the one or more determined optical measurements for lens construction by shaping a surface or a contour of the configurable parametric model to match the quantified portion of the anatomic feature of the individual.

22. The method of claim 21, wherein the one or more optical measurements include pupillary distance, vertex distance, pantoscopic tilt, frame wrap, and/or lens height of the lens portion of the configurable parametric model relative to pupils of the anatomic model of the individual'"'"'s face.

23. The method of claim 21, the step of identifying and quantifying one or more geometric features of the anatomic model of the individual'"'"'s face further comprising:

determining a location of the individual'"'"'s eyes, a center of the individual'"'"'s nose, and/or a vertical position of the individual'"'"'s face based on the anatomic model of the individual'"'"'s face.

24. The method of claim 21, further comprising:

determining the configurable parametric model by generating one or more geometric parameters of the configurable parametric model based on the identified and quantified one or more geometric features of the anatomic model of the individual'"'"'s face.

25. The method of claim 21, further comprising:

generating an electronic file comprising instructions for manufacturing a physical embodiment of the individual-specific eyewear product according to the determined configurable parametric model, wherein the physical embodiment of the individual-specific eyewear product includes progressive lenses.