Rapid prototyping of optical components, particularly lenses, for producing customized optical surface shapes

A method for producing at least one optical component (1), comprising the steps of:

• a1) providing at least one cavity (2), wherein the at least one cavity (2) is delimited on a second side opposing a first side by a surface (6a) of a second membrane portion (6), wherein a shape of the second membrane portion (6) is adjustable,
• b1) filling a liquid material (4) into the at least one cavity (2), so that the liquid material (4) contacts the surface (6a) of the second membrane portion (6),
• c1) adjusting a shape of a first surface (4a) of the liquid material (4) and adjusting the shape of the second membrane portion (6),
• d1) curing the liquid material (4) filled into the at least one cavity (2) so that the liquid material becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein a shape of the first interface (40a) is defined by the shape of the first surface (4a), and so that the liquid material forms a second interface (40b) of the at least one optical component (1), which second interface (40b) comprises a shape defined by a shape of the surface (6a) of the second membrane portion (6), and
• e2) the optical component comprises the rigid material (40) and the first interface (40a) is an optical surface of the optical component (1).

A method for producing at least one optical component (1), comprising the steps of:

• a1) providing at least one cavity (2) and a carrier (9), particularly for carrying the at least one optical component (1),
• b1) filling a liquid material (4) into the at least one cavity (2),
• c1) adjusting a shape of a first surface (4a) of the liquid material (4),
• d1) curing the liquid material (4) filled into the at least one cavity (2) so that the liquid material (4) becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein a shape of the first interface (40a) is defined by the shape of the first surface (4a), and either:
• e1) forming the at least one optical component by means of a molding process, wherein the first interface (40a) provides at least one surface of a molding tool, the shape of an optical surface of the optical component (1) is formed by means of the first interface (40a), the carrier is fixedly attached to the optical component (1), and the carrier (90) forms a mount for the at least one optical component (1), or
• e2) the optical component comprises the rigid material (40) and the first interface (40a) is an optical surface of the optical component (1), the carrier (9) is fixedly attached to the rigid material (40), and the carrier (90) forms a mount for the at least one optical component (1).