PRESCRIPTION LENS MANUFACTURING
A method of making a customized lens includes providing a first substrate having a first surface, the first surface being a non-flat surface; placing an optical film in contact with the first surface; bringing a layer of a first material into contact with the optical film; and curing the layer of the first material to form a lens. The optical film has a lower surface roughness than the first surface.
1 . A method of making a customized lens, the method comprising:
providing a first substrate having a first surface, the first surface being a non-flat surface;
placing an optical film in contact with the first surface;
bringing a layer of a first material into contact with the optical film; and
curing the layer of the first material to form a lens,
wherein the optical film has a lower surface roughness than the first surface.
2 . The method of claim 1 , further comprising additively manufacturing the first substrate having the first surface.
3 . The method of claim 1 , wherein the first substrate is porous.
4 . The method of claim 1 , wherein channels are defined in the first substrate.
5 . The method of claim 1 , including applying a vacuum through the first substrate.
6 . The method of claim 1 , wherein the first material includes one or more monomers.
7 . The method of claim 1 , wherein the optical film is made of a second material, and the first material subsequent to the curing and the second material have matching refractive indices.
8 . The method of claim 7 , wherein the optical film includes at least one of: poly-methyl methacrylate (PMMA), cyclic olefin copolymer (COC), cyclo-olefin Polymer (COP), or polycarbonate.
9 . The method of claim 1 , wherein the first material includes at least one of: poly-methyl methacrylate (PMMA), cyclic olefin copolymer (COC), cyclo-olefin Polymer (COP), polycarbonate, polystyrene, or polyurethanes.
10 . The method of claim 1 , wherein the optical film includes an optically specular surface.
11 . The method of claim 1 , wherein a thickness of the optical film is 100 microns or greater.
12 . The method of claim 11 , wherein the thickness of the optical film is a function of a curvature of the first surface.
13 . The method of claim 1 , further comprising placing a second substrate having a second surface into contact with the layer of the first material.
14 . The method of claim 13 , wherein the second surface forms an optically specular flat surface of the lens.
15 . The method of claim 13 , wherein curing comprises propagating ultraviolet light within the second substrate via total internal reflection.
16 . The method of claim 1 , further comprising depositing an optical coating on the optical film.
17 . A method, comprising:
providing a first optical element; and
forming a lens according to the method of claim 1 while the first material is in contact with the first optical element so that the formed lens is integrated with the first optical element.
18 . A lens, comprising:
an optical film defining a first surface of the lens, the first surface being a non-flat surface; and
a cured material in contact with the first surface and defining a second surface of the lens opposite to the first surface.
19 . The lens of claim 18 , wherein a thickness of the optical film is 100 microns or greater.
20 . The lens of claim 18 , wherein the cured material and the optical film have matching refractive indices.