Methods for formation of an ophthalmic lens with an insert utilizing voxel-based lithography

A method of forming an ophthalmic lens, the method comprising:

• placing the insert proximate to a specialized well, wherein the specialized well is configured to contain a reactive monomer mixture, and wherein after placement the insert is supported upon tabs that comprise the specialized well;
• placing a forming optic proximate to the insert, wherein the forming optic comprises a forming surface with dimensions and curvature consistent with a back curve of an ophthalmic lens;
• adding the reactive monomer mixture to the specialized well in a quantity sufficient to contact the forming surface and at least partially engulf the insert;
• forming a lens precursor by exposing the reactive monomer mixture to actinic radiation through the forming optic, wherein the actinic radiation is configured to control polymerization on a voxel by voxel basis over the forming surface, and wherein the lens precursor comprises a first surface portion in contact with the forming optic, wherein the first surface portion comprises an optical quality surface, a second surface portion, wherein the second surface portion comprising non-fluent polymerized material, and a third surface portion comprising non-voxel fluent partially polymerized material separate from the first reactive monomer mixture, wherein the third surface portion is located on a distal end of the lens precursor from the forming surface;
• removing the forming optic, the insert, and the lens precursor from contact with the reactive monomer mixture, wherein the lens precursor comprises non-fluent polymerized material capable of securing the insert to the lens precursor;
• forming the ophthalmic lens with the insert by exposing the fluent partially polymerized material to actinic radiation;
• and
• removing the ophthalmic lens from the forming optic.

A method of forming an ophthalmic lens, the method comprising:

• placing a forming optic in contact with a reactive monomer mixture, wherein the forming optic comprises a forming surface with dimensions and curvature consistent with an ophthalmic lens;
• forming a lens precursor form by exposing the reactive monomer mixture to actinic radiation, wherein the actinic radiation is configured to control polymerization on a voxel by voxel basis over the forming surface;
• removing the forming optic and the lens precursor from contact with the bath of reactive monomer mixture, wherein the lens precursor comprises and a first surface portion in contact with the forming optic, wherein the first surface portion comprises an optical quality surface, a second surface portion, the second surface portion comprising non-fluent polymerized material, and a third surface portion comprising non-voxel fluent partially polymerized material separate from the first reactive monomer mixture, wherein the third surface portion is located on a distal end of the lens precursor from the forming surface;
• releasing the first lens precursor from the forming optic into a holding fixture;
• placing an insert proximate to the first surface, the second surface, or the third surface, wherein the placing allows for a region to be formed that may at least partially surround the insert with reactive monomer mixture during processing;
• immersing the insert within a bath of the reactive monomer mixture, wherein the immersing occurs while the insert is in contact with the lens precursor in the holding fixture;
• forming an ophthalmic lens with insert by exposing the reactive monomer mixture to actinic radiation;
• and
• removing the ophthalmic lens from the bath.

A method of forming an ophthalmic lens, the method comprising:

• placing a forming optic in contact with a reactive monomer mixture, wherein the forming optic comprises a forming surface with dimensions and curvature consistent with a front curve of an ophthalmic lens;
• forming a lens precursor form by exposing the reactive monomer mixture to actinic radiation, wherein the actinic radiation is configured to control polymerization on a voxel by voxel basis over the forming surface;
• removing the forming optic and the lens precursor from contact with the reactive monomer mixture, wherein the lens precursor comprises a first surface portion in contact with the forming optic, wherein the first surface portion comprises an optical quality surface, a second surface portion, the second surface portion comprising non-fluent polymerized material and located on the distal end of the forming surface, and a third surface portion comprising non-voxel fluent partially polymerized material separate from the reactive monomer mixture, wherein the third surface portion is located on a distal end of the lens precursor from the forming surface;
• releasing the lens precursor from the forming optic, wherein the releasing places the lens precursor proximate to a front curve mold, wherein a surface portion of the lens precursor comprising a convex surface is in contact with the front curve mold;
• placing an insert proximate to the second surface portion formed by the releasing, wherein the placement allows for at least a partial encapsulation of the insert within an ophthalmic lens;
• depositing the reactive monomer mixture on a back curve portion of the insert;
• placing a back curve mold proximate to the front curve mold, wherein the placement causes the reactive monomer mixture to engulf the insert and after further processing to encapsulate the insert into the lens precursor;
• forming the ophthalmic lens by exposing the reactive monomer mixture to the actinic radiation, wherein the ophthalmic lens comprises the lens precursor and the insert;
• and
• releasing the ophthalmic lens from the front curve mold and the back curve mold.