OPHTHALMIC DEVICE FORMED BY ADDITIVE FABRICATION AND METHOD THEREOF
An ophthalmic device is formed by additive fabrication, the optical device having an 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 . An ophthalmic device having an optical surface and a plurality of additive fabrication lamina, wherein at least one of the plurality of additive fabrication lamina is formed from sub-micron sized particulates.
2 . The ophthalmic device of claim 1 wherein at least portions of each of the plurality of additive fabrication lamina is formed from a UV curable material.
3 . The ophthalmic device of claim 1 wherein at least portions of each of the plurality of additive fabrication lamina are formed from an IR curable material.
4 . (canceled)
5 . (canceled)
6 . (canceled)
7 . (canceled)
8 . (canceled)
9 . The ophthalmic device of claim 1 wherein each of the plurality of additive fabrication lamina has a thickness of less than 1 micron.
10 . The ophthalmic device of claim 1 wherein the ophthalmic device is a lens.
11 . The ophthalmic device of claim 1 wherein the ophthalmic device is a corrective lens.
12 - 20 . (canceled)
21 . The ophthalmic device of claim 1 , wherein at least portions of each of the plurality of additive fabrication lamina is formed from a polymerizable material.
22 . The ophthalmic device of claim 21 , wherein the polymerizable material is a polymerizable hydrophilic, siloxy-containing monomeric liquid material.
23 . The ophthalmic device of claim 1 wherein the device is suitable for placement in or on an eye.
24 . The ophthalmic device of claim 1 wherein each of the plurality of additive fabrication lamina is formed from sub-micron sized particulates.
25 . The ophthalmic device of claim 1 wherein at least portions of each of the plurality of additive fabrication lamina have the same composition.
26 . The ophthalmic device of claim 1 wherein at least one of the plurality of additive fabrication lamina is formed from nano-sized particulates.
27 . A method of making an ophthalmic device including an optical surface, the method comprising:
depositing a plurality of additive fabrication lamina, including at least a first lamina formed of a first plurality of sub-micron sized ophthalmic device forming particulates; and,
stimulating the first lamina of particulates to form a first solidified layer forming at least a first portion of the ophthalmic device.
28 . The method of claim 27 , wherein the step of depositing includes depositing a sacrificial material within the first lamina.
29 . The method of making an ophthalmic device of claim 27 further comprising:
depositing a second lamina formed of a second plurality of sub-micron sized ophthalmic device forming particulates on the first solidified layer; and,
stimulating the second lamina of particulates to form a second solidified layer forming a second portion of the ophthalmic device.
30 . The method of claim 29 , wherein the step of depositing the first lamina includes depositing submicron particulates in a first position relative to a stage supporting the first lamina, and wherein the step of depositing the second lamina includes depositing submicron particulates in a second position relative to the stage.
31 . The method of claim 30 , wherein the step of depositing the second lamina includes moving the stage supporting the first lamina a predetermined submicron distance relative to a dispensing head dispensing the second plurality of sub-micron sized ophthalmic device forming particulates.
32 . The method of claim 27 , wherein the first plurality of ophthalmic device forming particulates includes a polymerizable material.
33 . The method of claim 32 , wherein the polymerizable material is a polymerizable hydrophilic, siloxy-containing monomeric liquid material.
34 . The method of claim 27 , wherein sub-micron sized particulates of ophthalmic device forming material are deposited as liquid droplets from a dispensing head.