Custom contact lens molding system and methods
Apparatus and methods for manufacturing custom contact lenses and molds is provided wherein a reconfigurable mold has a cavity including deformable surface that is deformed by an array of actuators to define a specified surface contour that will result in a desired wavefront. The specified surface contour may be imparted to moldable material deposited in the cavity, and the array of actuators may be repositioned to optimize the vision correction provided by the custom contact lens. Methods of using the reconfigurable mold to manufacture custom contact lens molds also are provided.
1 . Apparatus for molding a custom contact lens comprising:
a housing that partially encloses a cavity;
a deformable surface coupled to the housing to define a wall surface of the cavity;
an array of actuators disposed in the housing in contact with the deformable surface to selectively impart localized deflections to the deformable surface to define a surface contour; and
an actuator controller coupled to the array of actuators to control actuation of the array of actuators.
2 . The apparatus of claim 1 further comprising a system controller that specifies a desired deformation of the deformable surface.
3 . The apparatus of claim 1 further comprising a support member that partly defines the wall surface of the cavity.
4 . The apparatus of claim 3 wherein the support member is transparent to light of specified wavelengths.
5 . The apparatus of claim 4 further comprising a measuring system that measures the surface contour.
6 . The apparatus of claim 4 further comprising a curing means for curing a moldable material deposited within the cavity.
7 . The apparatus of claim 6 wherein the curing means comprises a heat source.
8 . The apparatus of claim 6 wherein the curing means comprises a light source.
9 . The apparatus of claim 5 wherein the measuring system is an interferometer.
10 . The apparatus of claim 1 further comprising a reservoir of moldable material coupled to the housing.
11 . Apparatus for molding a custom contact lens mold comprising:
a housing that partially encloses a cavity;
a deformable surface coupled to the housing to define a wall surface of the cavity;
an array of actuators disposed in the housing in contact with the deformable surface to selectively impart localized deflections to the deformable surface to define a surface contour; and
an actuator controller coupled to the array of actuators to control actuation of the array of actuators.
12 . The apparatus of claim 11 further comprising a system controller that specifies a desired deformation of the deformable surface.
13 . The apparatus of claim 11 further comprising a support member that partly defines the wall surface of the cavity.
14 . The apparatus of claim 13 wherein the support member is transparent to light of specified wavelengths.
15 . The apparatus of claim 14 further comprising a measuring system that measures the surface contour.
16 . The apparatus of claim 14 further comprising a curing means for curing a moldable material deposited within the cavity.
17 . A method for forming a custom contact lens comprising:
providing a reconfigurable mold comprising a deformable surface that partly defines a wall surface of a cavity and an array of actuators configured to impart localized deflections on the deformable surface;
inserting moldable material into the cavity; and
actuating the array of actuators to deform the deformable surface to impart a specified surface contour on the moldable material to produce a desired wavefront; and
curing the moldable material to form the custom contact lens.
18 . The method of claim 17 further comprising inputting information for a desired custom contact lens configuration.
19 . The method of claim 18 further comprising translating the information into localized deflections of the array of actuators.
20 . The method of claim 17 further comprising:
measuring the surface contour imparted to the moldable material with a measuring device;
comparing a measured surface contour to the specified surface contour; and
repositioning at least some of the array of actuators prior to curing the moldable material.