Ophthalmic device formed by additive fabrication and method thereof
An ophthalmic device is formed by additive fabrication, the optical device having optical surface with a surface roughness on the order of less than 10 microns. A method is provided for making an ophthalmic device including an optical surface having a surface roughness of less than 10 microns by depositing on a stage in a first relative position a first lamina of particulates having a size less than 10 microns and in select configurations less than two microns and certain configurations less than one micron, and, synergistically stimulating the first lamina of particulates to form a first solidified layer.
1. A method of making an ophthalmic device including an optical surface, the method comprising:
(a) depositing a first lamina formed of a first plurality of ophthalmic device forming particulates, the first plurality of ophthalmic device forming particulates selected to form a portion of the ophthalmic device in response to synergistic stimulation; and
(b) synergistically stimulating the first lamina of ophthalmic device forming particulates to form a first solidified layer, a portion of the first solidified layer forming a portion of the ophthalmic device.
2. The method of claim 1 , wherein the step of depositing includes depositing a sacrificial material with the first lamina.
3. The method of claim 1 , further comprising depositing, on the first solidified layer, a second lamina formed of a second plurality of ophthalmic device forming particulates, the second plurality of ophthalmic device forming particulates selected to form a second portion of the ophthalmic device in response to synergistic stimulation.
4. The method of claim 3 , further comprising synergistically stimulating the second lamina of ophthalmic device forming particulates to form a second solidified layer.
5. The method of claim 1 , wherein the ophthalmic device Conning particulates in the depositing step include a liquid from a dispensing head.
6. The method of claim 1 , wherein the step of synergistically stimulating the first lamina of ophthalmic device forming particulates includes curing the first lamina with one of ultra-violet and infrared radiation.
7. The method of claim 1 , wherein the step of depositing the first lamina includes moving a stage supporting the first lamina a predetermined submicron distance relative to a dispensing head.
8. The method of claim 3 , wherein the step of depositing the second lamina includes moving a stage supporting the first lamina a predetermined submicron distance relative to a dispensing head.
9. The method of claim 1 , wherein the step of depositing the first lamina includes moving a dispensing head a predetermined submicron distance relative to a stage supporting the first lamina.
10. The method of claim 1 , wherein the ophthalmic device is suitable for placement in or on an eye.
11. The method of claim 3 , wherein the first lamina and the second lamina have the same composition.
12. A method of forming an ophthalmic device having an optical surface, the method comprising depositing by additive fabrication a plurality of bonded laminae, each lamina formed of a plurality particulates selected to form a portion of the ophthalmic device in response to synergistic stimulation, at least a portion of one of the plurality of bonded laminae defining a portion of the optical surface of the ophthalmic device.
13. The method of claim 12 , further comprising forming each of the lamina to have a thickness of less than 10 microns.
14. The method of claim 12 , wherein the ophthalmic device is suitable for placement in or on an eye.
15. The method of claim 12 , wherein each of the plurality of bonded laminae have the same composition.
16. A method of making an ophthalmic device including an optical surface, the method comprising:
(a) depositing a first lamina having a first plurality of ophthalmic device forming particulates, the first plurality of ophthalmic device forming particulates selected to form a first portion the ophthalmic device in response to synergistic stimulation;
(b) synergistically stimulating the first lamina of ophthalmic device forming particulates to form a first solidified layer, a portion of the first solidified layer forming the first portion of the ophthalmic device;
(c) depositing, on the first solidified layer, a second lamina having a second plurality of ophthalmic device forming particulates, the second plurality of ophthalmic device forming particulates selected to form a second portion of the ophthalmic device in response to synergistic stimulation; and
(d) synergistically stimulating the second lamina of ophthalmic device forming particulates to form a second solidified layer, the second solidified layer forming the second portion of the ophthalmic device.
17. The method of claim 16 , wherein a portion of the second solidified layer forms a portion of the optical surface of the ophthalmic device in response to the synergistic stimulation.
18. The method of claim 16 , wherein the first lamina has a thickness less than ten microns.
19. The method of claim 16 , wherein the first lamina and the second lamina have the same composition.
20. The method of claim 16 , wherein the ophthalmic device is suitable for placement in or on an eye.