SEE-THROUGH COMPUTER DISPLAY SYSTEMS

1 . A method for manufacturing a solid prism with a flat reflecting surface for a head-worn display comprising:

a. molding a solid prism of an optical material with one or more optically powered surfaces and at least one planar surface;

b. after molding, applying a drop of transparent UV curing adhesive with a refractive index that is index matched to the optical material of the flat surface;

c. applying a flat reflective plate to the drop of adhesive;

d. allowing the adhesive to wick across an interface between the planar surface and the flat reflective plate without applying pressure to the flat reflective plate to avoid distorting the flat reflective plate, until the entire interface is covered by adhesive; and

e. applying UV light to the interface to cure the adhesive and form a solid prism with a flat reflective surface.

2 . The method of claim 1 wherein the flat reflective plate is applied so a reflective side of the flat reflective plate contacts the adhesive so the reflective side is internal to the solid prism with a flat reflective surface.

3 . The method of claim 1 wherein the flat reflective plate is a mirror.

4 . The method of claim 1 wherein the flat reflective plate is a partial mirror.

5 . The method of claim 1 wherein the flat reflective plate is a reflective polarizer.

6 . The method of claim 5 wherein the reflective polarizer contacts the adhesive so the reflective polarizer is internal to the solid prism with a flat reflective surface.

7 . The method of claim 1 wherein the adhesive fills a sink mark on the planar surface.