Lens casting with deformable molds

1. A method for forming an optical element, the method comprising:

providing a precursor to a mold, wherein the mold includes a deformable surface overlying a chamber, wherein an outer periphery of the deformable surface is supported by a frame that peripherally surrounds the chamber;

shaping the deformable surface according to a surface profile by:

adjusting a fluid pressure within the chamber to introduce a spherical geometry into the deformable surface; and

driving a plurality of actuators that are configured to introduce a cylindrical deformation into the deformable surface; and

solidifying the precursor while the deformable surface is shaped according to the surface profile to form the optical element.

2. The method of claim 1 , wherein the precursor comprises an optically transparent resin, amorphous polymer, polymer solution, or low melting temperature glass.

3. The method of claim 2 , wherein solidifying the precursor comprises exposing the precursor to electromagnetic radiation.

4. The method of claim 1 , wherein the deformable surface comprises a transparent material selected from the group consisting of a polymer, a glass, a ceramic, and sapphire.

5. The method of claim 1 , wherein the plurality of actuators comprise bladders.

6. The method of claim 1 , wherein adjusting the fluid pressure introduces the spherical geometry by introducing a axisymmetric deflection of the deformable surface and driving the plurality of actuators introduces the cylindrical deformation by introducing a non-axisymmetric deflection of the deformable surface.

7. The method of claim 6 , further comprising controlling the axisymmetric deflection and the non-axisymmetric deflection in a manner that decouples the axisymmetric deflection from the non-axisymmetric deflection.

8. The method of claim 1 , wherein solidifying the precursor comprises driving a plurality of individually controlled heat sources to different power levels or driving a plurality of individually controlled ultraviolet light sources to different emission levels.

9. The method of claim 1 , further comprising forming a release layer or an antireflective coating over the deformable surface prior to providing the precursor to the mold.

10. The method of claim 1 , further comprising:

capturing an image of the deformable surface while the precursor is disposed within the mold; and

adjusting the fluid pressure within the chamber and/or adjusting one or more of the plurality of actuators in response to the image prior to solidifying the precursor.

11. The method of claim 10 , wherein capturing the image includes:

illuminating the deformable surface with illumination light that propagates through the precursor; and

receiving, by an image sensor, the illumination light through a lenslet array subsequent to the illumination light reflecting off of or passing through the deformable surface.

12. The method of claim 1 , further comprising removing the optical element from the mold by driving one or more of the plurality of actuators.

13. The method of claim 1 , wherein the optical element comprises an ophthalmic lens.

14. The method of claim 1 , further comprising forming a reflective coating over a surface of the optical element.

15. A casting assembly for forming an optical element, the casting assembly comprising:

a deformable surface that is overlying a chamber and that is shaped by adjusting a fluid pressure to introduce a spherical geometry into the deformable surface;

a frame that peripherally surrounds the chamber, wherein an outer periphery of the deformable surface is supported by the frame; and

a plurality of actuators that are configured to introduce a cylindrical deformation into the deformable surface.

16. The casting assembly of claim 15 , wherein the plurality of actuators comprise deformable bladders configured to exert a localized pressure along the periphery of the deformable surface.

17. A casting assembly for forming an optical element, the casting assembly comprising:

a deformable surface shaped by adjusting a pressure overlying a fluid-filled chamber to introduce a spherical geometry into the deformable surface;

a frame that peripherally surrounds the fluid-filled chamber, wherein an outer periphery of the deformable surface is supported by the frame; and

a plurality of actuators that are configured to introduce a cylindrical deformation into the deformable surface.

18. The casting assembly of claim 17 , wherein changes to pressure within the fluid-filled chamber and actuation of the plurality of actuators are independently controlled.

19. The method of claim 1 , wherein adjusting the fluid pressure is performed independently from driving the plurality of actuators.

20. The casting assembly of claim 15 , further comprising a closed-loop system that adjusts the fluid pressure of the chamber.