Eyewear lens creation by additive manufacturing using improved light pattern techniques

A system for lens creation by layerless additive manufacturing using improved light patterns, the system comprising:

• a substrate at least partially transparent to a curing radiation having an improved light pattern;
• a photocurable resin on top of the substrate;
• a spatial light modulator for illuminating the resin with the curing radiation so that the curing radiation first passes through a diffuser, then the substrate, then enters the resin to create a layerless polymerized lens during a single illumination of the curing resin by the curing radiation;
• wherein:
• the improved light pattern is such that each point in the resin is illuminated by light from a set of points in the diffuser covering at least 10% of a total area of a surface of the diffuser towards the substrate;
• and one of:
• the improved light pattern of the curing radiation is improved and optimized to compensate for at least one of:
• distortion generated by the spatial light modulator, a distortion effect of using curved diffusers, a variability of the spatial response of the light modulator, or for a lack of linearity of the irradiance response of the spatial light modulator;
• or
• the improved light pattern changes over time while the improved light pattern is projected onto the diffuser surface further away from the substrate.