Waveguides with integrated optical elements and methods of making the same

1. A waveguide comprising:

a polymer layer comprising substantially optically transparent material having first and second major surfaces configured such that light containing image information can propagate through said polymer layer being guided therein by reflecting from said first and second major surfaces via total internal reflection,

wherein said first surface includes first smaller and second larger surface portions monolithically integrated with said polymer layer and with each other, said first smaller surface portion comprising at least a part of an in-coupling optical element configured to couple light incident on said in-coupling optical element into said polymer layer for propagation therethrough by reflection from said second major surface and said second larger surface portion of said first major surface,

wherein said first smaller surface portion comprises a tilted surface portion forming an indentation in said polymer layer, wherein said indentation has a depth that is less than the thickness of the polymer layer and that is at least ½ the thickness of the polymer layer,

wherein said polymer layer including said at least a part of said in-coupling optical element comprises a molded optic such that the first and second surfaces have a surface roughness between about 0.1 nm to about 2.0 nm.

2. The waveguide of claim 1 , wherein said in-coupling optical element comprises a turning mirror configured to deflect light containing image information in the waveguide.

3. The waveguide of claim 2 , wherein said turning mirror comprises said first smaller surface portion of said first major surface tilted with respect to said second larger surface portion of said first major surface and said second major surface.

4. The waveguide of claim 2 , wherein said turning mirror has optical power.

5. The waveguide of claim 4 , wherein said powered turning mirror comprises said first smaller surface portion of said first major surface curved with respect to said second larger surface portion of said first major surface and said second major surface.

6. The waveguide of claim 2 , wherein said turning mirror further comprises metallization disposed on said first smaller surface portion of said first major surface.

7. The waveguide of claim 1 , wherein said in-coupling optical element comprises a lens.

8. The waveguide of claim 7 , wherein said lens comprises said first smaller surface portion of said first major surface curved with respect to said second larger surface portion of said first major surface and said second major surface.

9. The waveguide of claim 1 , further comprising a grating.

10. The waveguide of claim 9 , wherein said grating has an undulating surface relief.

11. An optical system comprising:

one or more waveguides comprising the waveguide of claim 1 .

12. The optical system of claim 11 , wherein said one or more waveguides comprise at least two of the waveguides.

13. The optical system of claim 11 , wherein the optical system is a head mounted display system configured to project light to an eye of a user to display augmented reality image content in a vision field of said user.

14. The optical system of claim 13 , further comprising

a frame configured to be supported on a head of the user;

an image projector configured to project an image; and

an eyepiece disposed on the frame, said eyepiece configured to direct light into said user's eye to display augmented reality image content to the user's vision field, at least a portion of said eyepiece being transparent and disposed at a location in front of the user's eye when the user wears said head-mounted display system such that said transparent portion transmits light from the environment in front of the user to the user's eye to provide a view of the environment in front of the user, said eyepiece comprising said one or more waveguides.

15. The optical system of claim 14 , wherein the image projector comprises a scanning fiber display.