STTR Phase I: On-demand optical printing of high-performance personalized eyeglass lenses

这个SBIR第一阶段项目将展示利用低成本光学打印机生产眼镜片的可行性，这将使使用低成本光学打印机制造高质量的镜片成为可能。其结果是开发了一种商业模式，在这种模式下，只需一次就诊，就可以进行眼科检查，打印处方镜片，组装和分发眼镜。在完成眼科检查的屈光部分后，镜片处方将以电子方式传输到光学镜片打印机。镜片毛坯经过紫外线和防划痕保护处理后，将包含一层可接受和冻结个性化处方的激光可写光聚合物层。用这种方法生产的眼镜的光学质量将与传统镜片相同或更高，而且生产成本只有传统镜片的一小部分。这种生产眼镜片的方法不仅减少了确保眼镜安全的周转时间，而且同样重要的是，将显著降低眼镜的生产成本，从而降低零售价格。考虑到超过60%的美国人口佩戴眼镜，以及更高比例的家庭成员依赖眼镜，该项目将使绝大多数美国纳税人受益。STTR第一阶段提案的目标是证明三项联合创新的可行性：1)用于记录感光眼镜片毛坯的高速光学打印机；3)新型梯度折射率衍射光学元件，与现有的透镜制造技术相比，这种光学元件提供了显著改善的制造成本、视觉性能和更轻的重量。目标应用将是用紧凑、廉价的光学打印机制造的低成本、低阶像差和高阶像差校正眼镜镜片。用这种基于光的工艺生产的镜片将赶上或超过目前用计算机数控铣床制造的自由形状镜片的光学质量，成本在25万美元到50万美元之间。这一拟议的镜片制造创新使眼镜配发业务模式得以发展，从而消除了对传统集中式眼镜实验室、相关分销网络、全面的镜片毛坯库存以及购买处方眼镜的漫长等待时间的需要。这项技术的开发将使眼科实践更好地为患者服务，使现场制造更符合眼睛缺陷的优质矫正镜片成为可能。到第一阶段结束时，目标是优化光聚合物材料，改进光源，并完成光学打印机的工程模型。

This SBIR Phase I project will demonstrate the feasibility of producing ophthalmic lenses utilizing a low cost optical printer that will enable the fabrication of superior quality lenses with a low cost optical printer. The result is development of a business model where an eye exam is administered, prescription lenses are printed and glasses assembled and dispensed in a single visit. Upon completing the refraction portion of the eye exam, the lens prescriptions will be electronically transferred to the optical lens printer. The lens blanks, pre-treated for UV and anti-scratch protection, will contain a laser writable photopolymer layer that accepts and freezes the personalized prescriptions. Eyeglasses produced with this method will be of equal or higher in optical quality compared to traditional lenses and can be produced at a fraction of the cost of conventional lenses. This method of producing ophthalmic lenses both reduces the turnaround time for securing eyeglasses but equally important, will significantly reduce the cost for producing eyeglasses translating to lower the retail prices. Considering that over 60% of the US population wears glasses and a much high percentage of families have members that depend on glasses, this project will benefit the vast majority of US taxpayers.The goal of this STTR Phase 1 proposal is to demonstrate the feasibility of three coupled innovations: 1) a high-speed optical printer for 2) photosensitive ophthalmic lens blanks that record 3) novel gradient-index diffractive optics which provide dramatically improved fabrication cost, visual performance and lighter weight over existing lens making technologies. The target application will be low cost, low and higher order aberration correcting eyeglass lenses fabricated with a compact, inexpensive optical printer. Lenses produced with this light based process will match or exceed the optical quality of current free form lenses made with computer numerical controlled milling machines costing in the range of $250k to $500k. This proposed lens making innovation enables the development of an eyeglass dispensing business model that could eliminate the need for conventional centralized eyeglass labs, the associated distribution networks, a comprehensive inventory of lens blanks and the long wait times for procuring prescription eyeglasses. The developments of this STTR will allow ophthalmic practices to better serve their patients, enabling on-site fabrication of superior corrective lenses that more closely match eye deficiencies. By the end of phase I, the goal is to optimize the photopolymer materials, refine the light sources and complete an engineering model of the optical printer.