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

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.