System and method for low-stress optical lens using a 3D-print correction technique

A method to form a corrected optical lens, the method comprising:

• receiving an inner layer, wherein the inner layer comprises a low stress optical lens;
• and
• forming an outer layer comprising one or more corrective layers on an outer surface of the inner layer by:
• scanning the outer surface of the inner layer to identify at least one surface imperfection on the outer surface with respect to a particular predetermined contour of the inner layer;
• generating a surface characterization file based on the outer surface scan that includes a correction to the at least one surface imperfection based on the particular predetermined contour of the inner layer;
• and
• forming the one or more corrective layers on the outer surface of the inner layer via three-dimensional (3D) printing to correct the at least one surface imperfection and form the particular predetermined contour based on the correction in the surface characterization file as input to a 3D printer.

A system to form a corrected optical lens, the system comprising:

• a lens generator to provide an inner layer comprising a low stress optical lens;
• a three-dimensional (3D) scanner to scan an outer surface of the inner layer to identify at least one surface imperfection on the outer surface with respect to a particular predetermined contour of the inner layer;
• a 3D printer to form an outer layer by 3D printing one or more corrective layers on at least a portion of an outer surface of the inner layer to correct the at least one surface imperfection and form the particular predetermined contour;
• and
• a controller communicatively coupled to the lens generator, the 3D scanner, and the 3D printer, the controller to:
• generate a surface characterization file based on the outer surface scan that includes a correction to the at least one surface imperfection based on the particular predetermined contour of the inner layer;
• and
• provide the surface characterization file as input to the 3D printer for printing the one or more corrective layers.