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Eyewear lens production by additive techniques

  • US 9,952,448 B2
  • Filed: 11/11/2014
  • Issued: 04/24/2018
  • Est. Priority Date: 03/26/2014
  • Status: Active Grant
First Claim
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1. A method of producing a customized eyewear lens comprising:

  • a) obtaining a lens substrate comprising a first surface that will be nearest the eye when worn and a second surface that will be farthest from the eye when worn;

    b) calculating and generating an added material design to convert the lens substrate'"'"'s optical power to a desired optical power for the customized eyewear lens, wherein the desired optical power of the customized eyewear lens is discernibly different to the unaided eye from the lens substrate'"'"'s optical power;

    c) contacting at least a portion of at least one of the first and second surfaces of the lens substrate with a bulk source of a flowable radiation-polymerizable material; and

    d) while the lens substrate is in contact with the bulk source of flowable radiation-polymerizable material, irradiating the flowable radiation-polymerizable material with radiation from an irradiation assembly comprising at least one irradiating beam that is controlled for wavelength range, energy and spatial distribution to polymerize the flowable radiation-polymerizable material only in a selected area of irradiation, wherein the flowable radiation-polymerizable material is irradiated according to the added material design to form added material on the lens substrate and create the desired optical power of the customized eyewear lens, wherein the area of irradiation is controlled for spatial position relative to the lens substrate, and wherein the added material is integrally bonded to the lens substrate; and

    wherein external shaping structures are not used during the steps of contacting and irradiating the flowable radiation-polymerizable material.

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