Optical device and method

An optical device comprising:

• a light source configured to generate a light;
• a lens assembly off-axis from the light source and configured to receive the light, wherein the lens assembly includes a plurality of lenses and wherein the lens assembly has been truncated by removal of material from one or more of the lenses where an expected light beam is not predicted to pass;
• and
• a combiner configured to receive the light from the lens assembly via one or more optical elements and direct the light to form a virtual image at an exit pupil at a position of an eye of a user, wherein the combiner comprises a first inner optical surface form and a second outer optical surface form, wherein the first inner optical surface form and the second inner optical surface form are different to minimize deviations in an outside view from the combiner;
• wherein the one or more optical elements include
• a first optical device, the first optical device being an at least partially mirrored device, and
• a second optical device positioned substantially orthogonal relative to the at least partially mirrored device, and located intermediate the lens assembly and the at least partially mirrored device, the second optical device configured to receive the light from the lens assembly and transmit the light to the at least partially mirrored device.

The method of claim 22, wherein in operation, the optical device is configured to:

• emit, via a light source, a light to a the lens assembly, wherein one or more of the lenses is truncated where an expected light beam is not predicted to pass;
• direct, via one or more optical elements, the light towards a combiner;
• and
• direct, via the combiner, the light to form a virtual image at an exit pupil of the optical device;
• wherein the combiner comprises a first inner optical surface form and a second outer optical surface form, and wherein the first inner optical surface form and the second inner optical surface form are different to minimize deviations in an outside view from the combiner.

A method for making an optical device through which light can be directed, the method comprising:

• designing the optical device, the optical device including a lens assembly that includes a plurality of lenses;
• determining a light path through the design;
• identifying areas of the lens assembly through which no light is predicted to pass;
• and
• updating the design to truncate one of more of the lenses based on where the light is predicted to pass.