Ophthalmic device formed by additive fabrication and method thereof

12135,469

17/552063

December 15, 2021

An ophthalmic device is formed by additive fabrication, the optical device having 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.

Additive Ophthalmic Optics, LLC (Macedon, NY, US)

Additive Ophthalmic Optics, Inc. (Macedon, NY, US)

1. A method of making an ophthalmic device including an optical surface, the method comprising: (a) depositing a first lamina formed of a first plurality of ophthalmic device forming particulates, the first plurality of ophthalmic device forming particulates selected to form a portion of the ophthalmic device in response to synergistic stimulation; and (b) synergistically stimulating the first lamina of ophthalmic device forming particulates to form a first solidified layer, a portion of the first solidified layer forming a portion of the ophthalmic device.

2. The method of claim 1 , wherein the step of depositing includes depositing a sacrificial material with the first lamina.

3. The method of claim 1 , further comprising depositing, on the first solidified layer, a second lamina formed of a second plurality of ophthalmic device forming particulates, the second plurality of ophthalmic device forming particulates selected to form a second portion of the ophthalmic device in response to synergistic stimulation.

4. The method of claim 3 , further comprising synergistically stimulating the second lamina of ophthalmic device forming particulates to form a second solidified layer.

5. The method of claim 1 , wherein the ophthalmic device Conning particulates in the depositing step include a liquid from a dispensing head.

6. The method of claim 1 , wherein the step of synergistically stimulating the first lamina of ophthalmic device forming particulates includes curing the first lamina with one of ultra-violet and infrared radiation.

7. The method of claim 1 , wherein the step of depositing the first lamina includes moving a stage supporting the first lamina a predetermined submicron distance relative to a dispensing head.

8. The method of claim 3 , wherein the step of depositing the second lamina includes moving a stage supporting the first lamina a predetermined submicron distance relative to a dispensing head.

9. The method of claim 1 , wherein the step of depositing the first lamina includes moving a dispensing head a predetermined submicron distance relative to a stage supporting the first lamina.

10. The method of claim 1 , wherein the ophthalmic device is suitable for placement in or on an eye.

11. The method of claim 3 , wherein the first lamina and the second lamina have the same composition.

12. A method of forming an ophthalmic device having an optical surface, the method comprising depositing by additive fabrication a plurality of bonded laminae, each lamina formed of a plurality particulates selected to form a portion of the ophthalmic device in response to synergistic stimulation, at least a portion of one of the plurality of bonded laminae defining a portion of the optical surface of the ophthalmic device.

13. The method of claim 12 , further comprising forming each of the lamina to have a thickness of less than 10 microns.

14. The method of claim 12 , wherein the ophthalmic device is suitable for placement in or on an eye.

15. The method of claim 12 , wherein each of the plurality of bonded laminae have the same composition.

16. A method of making an ophthalmic device including an optical surface, the method comprising: (a) depositing a first lamina having a first plurality of ophthalmic device forming particulates, the first plurality of ophthalmic device forming particulates selected to form a first portion the ophthalmic device in response to synergistic stimulation; (b) synergistically stimulating the first lamina of ophthalmic device forming particulates to form a first solidified layer, a portion of the first solidified layer forming the first portion of the ophthalmic device; (c) depositing, on the first solidified layer, a second lamina having a second plurality of ophthalmic device forming particulates, the second plurality of ophthalmic device forming particulates selected to form a second portion of the ophthalmic device in response to synergistic stimulation; and (d) synergistically stimulating the second lamina of ophthalmic device forming particulates to form a second solidified layer, the second solidified layer forming the second portion of the ophthalmic device.

17. The method of claim 16 , wherein a portion of the second solidified layer forms a portion of the optical surface of the ophthalmic device in response to the synergistic stimulation.

18. The method of claim 16 , wherein the first lamina has a thickness less than ten microns.

19. The method of claim 16 , wherein the first lamina and the second lamina have the same composition.

20. The method of claim 16 , wherein the ophthalmic device is suitable for placement in or on an eye.

3986997 October 1976 Clark
4242381 December 1980 Goossens et al.
4575330 March 1986 Hull
5200121 April 1993 Hagmann et al.
5204055 April 1993 Sachs et al.
5316791 May 1994 Farber et al.
5362427 November 1994 Mitchell, Jr.
5386500 January 1995 Pomerantz et al.
5387380 February 1995 Cima et al.
5398193 March 1995 deAngelis
5510066 April 1996 Fink et al.
5854748 December 1998 Snead et al.
6036910 March 2000 Tamura et al.
6136252 October 2000 Bedal et al.
6196685 March 2001 Roffman et al.
6406658 June 2002 Manners et al.
6508971 January 2003 Leyden et al.
6726322 April 2004 Andino et al.
6808683 October 2004 Gilbert
6811805 November 2004 Gilliard
6834955 December 2004 Doshi
6864341 March 2005 Lai et al.
6864342 March 2005 Lai et al.
6881808 April 2005 Salamone et al.
6881809 April 2005 Salamone et al.
6888289 May 2005 Heilig et al.
6891010 May 2005 Kunzler et al.
6906162 June 2005 Salamone et al.
6908978 June 2005 Salamone et al.
6911173 June 2005 Farnworth
6951914 October 2005 Lai et al.
6956087 October 2005 Lai et al.
6989430 January 2006 Salamone et al.
6992162 January 2006 Salamone et al.
7005494 February 2006 Salamone et al.
7009023 March 2006 Salamone et al.
7009024 March 2006 Salamone et al.
7091299 August 2006 Salamone et al.
7101949 September 2006 Salamone et al.
7132492 November 2006 Lai et al.
7132493 November 2006 Lai et al.
7132494 November 2006 Salamone et al.
7138440 November 2006 Salamone et al.
7169874 January 2007 Salamone et al.
7176268 February 2007 Lai et al.
7188950 March 2007 Dreher et al.
7198639 April 2007 Lai et al.
7209797 April 2007 Kritchman et al.
7229594 June 2007 Renaud et al.
7235195 June 2007 Andino et al.
7279538 October 2007 Lai et al.
7297160 November 2007 Salamone et al.
7632540 December 2009 Kumar et al.
7802883 September 2010 Wright et al.
8303746 November 2012 Friel
8317505 November 2012 Widman et al.
20030035917 February 2003 Hyman
20040046287 March 2004 Andino et al.
20050012998 January 2005 Kumar
20050074616 April 2005 Harchanko et al.
20070103639 May 2007 Nellissen et al.
20070141114 June 2007 Muisener et al.
20070153387 July 2007 Pawlowski et al.
20080062381 March 2008 Doshi et al.
20080123049 May 2008 Volk
20080273073 November 2008 Oakley
2007104401 September 2007

Castle Island's Worldwide Guide to Rapid Prototyping: Three Dimensional Printing, http:home.att.net/castleisland/3dp.htm (Dec. 13, 2007). cited by applicant
Rev. Sci. Instrum.: Characterization of a sub-micron liquid spray for laser-plasma x-ray generation Issue Date: Nov. 1998; vol. 69, Issue 11, pp. 3780-3788. cited by applicant
DSM Somos®: Somos® 9420 EP White (dated Sep. 2006) (3 pages). cited by applicant
3D Systems Corporation News Release: FineLine Prototyping New Viper™ Pro SLA® System Exceeds Expectations Aug. 16, 2006. cited by applicant
Steinbeis-Transferzentrum Technische Beratung an Der Fachhochschule Mannheim: Expert Opinion of Prof. Dr.-Ing. Klaus-Jürgen Peschges: Stereolithography—Fused Deposition Modeling (Mannheim 1999). cited by applicant
EOS GmbH (Dec. 2005): EOS Technology Overview. cited by applicant
The POM Group, Inc. (© The POM Group, Inc., 2002): POM Tooling Capabilities Brochure. cited by applicant
Castle Island's Worldwide Guide to Rapid Prototyping: Rapid Prototyping Equipment, Software and Materials Printing the Future (http://home.att.net/˜castleisland/rp_int1.htm) (Jan. 2, 2007). cited by applicant
RP Tempering™ Technology News: Nano-Composite Technology Newsletter—vol. 3 (May 2006). cited by applicant
Zemike Polynoimials: 6 pages (http://grus.berkeley.edu/˜jrg/Aberrations/node11.html) (Dec. 4, 2006). cited by applicant
James C. Wyant: Chapter 1—Basic Wavefront Aberration Theory for Optical Metrology Copyright © 1992 by Academic Press, Inc.). cited by applicant
Z Corporation (© 2006 Z Corporation): ZScanner 700 Technical Specs. cited by applicant
Carnegie Mellon University: Spotlight News (Dec. 11, 2006) (www.mbic.cmu.edu/home.html). cited by applicant

edspgr.12135469