Casting of freeform ophthalmic lenses at a ferrofluidic surface

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Ophthalmic lens production technology is moving towards personalized freeform design to respond to the specific needs of individual patients. The freeform process allows for the correction of higher-order aberrations of the patient's eye that cannot be accounted for by regular, traditional eyeglass lens manufacturing. The objective of the current project is to assess the feasibility of producing freeform-like ophthalmic lenses by casting a monomer (liquid resin) on a ferrofluid surface. Ferrofluids can be deformed by the application of a magnetic field. In this innovative approach, personalized lenses will be produced by casting and curing a suitable resin at a ferrofluid surface of appropriate shape. The specific objectives of the project include the identification of optimal monomer and ferrofluid candidates, the replication of test surfaces in a laboratory setting, testing of the curing process when ferrofluid shape is controlled by a magnetic field and fabrication of a spherical surface prototype. The project brings together academic researchers, with expertise in ferrofuids, polymer chemistry and surface control using magnetic fields, and industrial partners with an intimate knowledge of the manufacture and marketing of eyeglass lenses. If shown to be viable, the new technology will lead to more, affordable, more precise eyewear for Canada.