Apparatus and method of fabricating a compensating element for wavefront correction using spatially localized curing of resin mixtures

A method for manufacturing a correcting element having a first transparent element, a second transparent element, and a layer of curable, refractive index changing resin mixture sandwiched therebetween, comprising:

• determining a three-dimensional spatial distribution of an index of refraction profile;
• focussing a light beam on a first location within the resin mixture to establish a first curing volume within the resin mixture;
• and
• refocussing the light beam to one or more subsequent positions within the resin mixture to establish additional curing volumes, wherein the first curing volume and the subsequent curing volumes collectively establish the predetermined three-dimensional spatial distribution of an index of refraction profile.

An apparatus for manufacturing a correcting element having at least one transparent element and an adjacent resin mixture layer wherein the resin mixture is curable upon exposure to radiation having a wavelength to render cured resin mixture, and the cured resin mixture creates a predetermined three-dimensional spatial distribution of an index of refraction profile, the apparatus comprising:

• at least one scanning unit;
• at least one light source coupled to the scanning unit and emitting a light beam containing the wavelength, the light beam converging to a focal point;
• a means for controlling the scanning unit to position the focal point within the resin mixture layer;
• and
• a means for controlling the scanning unit to move the focal point through the resin mixture layer to cure the resin mixture, the cured resin mixture establishing the predetermined three-dimensional spatial distribution of an index of refraction profile.

An apparatus for manufacturing a correcting element having at least one transparent element and an resin mixture layer wherein the resin mixture is curable upon exposure to radiation having a wavelength to establish a predetermined three-dimensional spatial distribution of index of refraction profile, the apparatus comprising:

• at least one optical fiber coupled to a radiation source, providing a suitable light source for curing the resin mixture;
• at least one optical relay imaging a target plane at an emitting end of the fiber to an image plane at the resin mixture layer;
• and
• at least one X-Y-Z translation mechanism attached to the fiber and positioning the fiber at the target plane such that the radiation emitted from the fiber is delivered by the optical relay to a corresponding image location at the image plane.

An apparatus for manufacturing a correcting element having at least one transparent element and an adjacent resin mixture layer wherein the resin mixture is curable upon exposure to radiation having a wavelength, and the cured resin mixture creates a predetermined three-dimensional spatial distribution of index of refraction, the apparatus comprising:

• an optical fiber bundle;
• a plurality of radiation sources, each source being coupled to at least one optical fiber in the bundle;
• a plurality of control units controlling the radiation intensity and the duration of the radiation for each source;
• and
• at least one optical relay imaging light from emitting ends of the fiber bundle to a target plane in the resin mixture layer.

A method for improving the performance of an optical instrument, comprising:

• determining optical aberrations of the optical instrument;
• determining a three dimensional spatial distribution of an index of refraction profile that compensates for the aberrations;
• providing at least one correcting element having a layer of curable, refractive index changing material, the providing act including:
• (a) directing a focusing light beam to a first position within the layer of material to form a curing volume within the material;
• and
• (b) moving the focusing light beam to one or more subsequent positions within the layer of material to form one or more subsequent curing volumes, wherein the curing volume and the subsequent curing volumes collectively form the predetermined three-dimensional spatial distribution of an index of refraction;
• and
• inserting the wave plate in a predetermined location of the instrument.

A method of improving the performance of an optical element, comprising:

• making a correcting element having a first transparent element, and a layer of curable, refractive index changing polymer sandwiched between the first transparent element and a first surface of the optical element, the making act comprising:
• (a) determining optical aberrations of the optical element, the polymer layer, and the first transparent element;
• (b) determining a three dimensional spatial distribution of an index of refraction profile to compensate for the aberrations;
• (c) positioning a focusing light beam to a first position within the layer of polymer to form a curing volume within the polymer;
• and
• (d) moving the focusing light beam to one or more subsequent positions within the layer of polymer to form one or more subsequent curing volumes wherein the curing volume and the subsequent curing volumes collectively form the predetermined three dimensional spatial distribution of an index of refraction.

A method of manufacturing a customized ophthalmic lens for a patient, comprising:

• determining aberrations of the eye of a patient;
• determining a location of a center of an entrance pupil of the eye relative to a spectacle frame;
• manufacturing a correcting element comprising a first transparent element, and a layer of curable, refractive index changing resin mixture, the manufacturing act including:
• (a) determining a three dimensional spatial distribution of an index of refraction profile compensating for the aberrations;
• (b) positioning a focusing light beam to a first position within the layer of polymer to form a curing volume within the resin mixture;
• (c) moving the focusing light beam to one or more subsequent positions within the layer of polymer to form one or more subsequent curing volumes wherein the curing volume and the subsequent curing volumes collectively form the predetermined three dimensional spatial distribution of an index of refraction profile.

A method of manufacturing progressive ophthalmic lenses customized to a patient's eye comprising:

• imaging en face for measuring the patient's pupils, his spectacle, and pupilary distance of the patient when the patient is presented with targets at distant and at near viewing locations;
• imaging 90 degrees en face for measuring tilt angles of the patient's head, a distance between a corneal apex to an ophthalmic lens, and a location of targets when the patient is presented with targets at distant and near viewing locations;
• calculating locations of optical centers on the ophthalmic lens for the patient's distant and near vision;
• and
• designing a progressive addition lens using the locations of the optical centers of the distant and near vision of the patient.

An apparatus for curing at least one monomer in a resin mixture at a plurality of cure locations to thereby establish an index of refraction profile in the resin mixture, comprising:

• at least one light source useful for curing the monomer;
• means for passing light from the light source to at least one of the plurality of cure locations in the resin mixture;
• and
• means for moving the light from one cure location to another cure location.