Design of multifocal contact lens with nurbs and shrinkage analysis on shell mold by injection molding process

Taipei, May 2018 Dissertation defense for the Degree of Doctor of Philosophy DESIGN OF MULTIFOCAL CONTACT LENS WITH NURBS AND SHRINKAGE ANALYSIS ON SHELL MOLD BY INJECTION MOLDING PROCESS presented by Vu Thi Lien Advisor: Prof Chao-Chang A Chen Committee : Prof Sen-Yeu Yang (Chair) Prof Jong-Woei Whang Dr Kuo-Cheng Huang Prof Pei-Jen Chung Dr Yi-Sha Ku Prof Chien-Yu Chen Prof Chao-Chang A Chen Tai ngay!!! Ban co the xoa dong chu nay!!! DEPARTMENT OF MECHANICAL ENGINEERING PRECISION MANUFACTURING LABORATORY OUTLINE Introduction Overview of contact lens design Specific studies A NURBS multifocal CLs with given optical power distribution B NURBS multifocal CLs with uniform optical power in center-distance zone C Minimization of shrinkage error of shell mold in injection molding process Conclusions and Recommendations 6/5/2018 Presbyopia and correction methods A loss of accommodation with age (>40) to focus on nearby objects when the crystalline lens becomes harder and loses elasticity and causes light to focus behind the retina Presbyopia correction with spectacles Presbyopic eye Retina https://www.improveeyesighthq.com/presbyopia.html Crystalline lens http://www.eyes-and-vision.com/presbyopia-eye-disorder.html Spectacles http://www.eyelandeyedoc.com/eyeglass-lensoptions/ blur Contact lens http://video.visiondirect.com/v/1396813785/aom-consumermoa-video-hi-res-mov-air-optix-contact/ Surgery (Effect is not long-lasting) blur Progressive addition lens Presbyopia corrections Multifocal contact lens • • • • http://metroeyedocs.com/boomer-lens.html http://www.allaboutvision.com/visionsurgery/presby-lasik.htm Multifocal Lasilk Better vision More attractive More convenient (sport activities) Not be affected by weather conditions Multifocal CLs for presbyopia Two vision distances (near and far) “Image jump” Focusing various vision distances within the area of pupil on retina at the same time (more natural) Dop=6.0 mm Power distributions of CLs for presbyopic correction [42-44] 6/5/2018 http://www.bausch.com.sg/en/our-products/contact-lenses/lenses-for-presbyopia/biotrueoneday-for-presbyopia/ Power profiles of commercial simultaneous multifocal CLs The power profile of a zonal-aspheric multifocal CL [87] [89] Additional (Add) powers (low, mid, high) from +0.75 to 3.50 D 6/5/2018 Problem statement • The demand for presbyopia CLs is very high with more and more requirements • None of available multifocal CL designs presents as the best design Lens shapes, materials and manufacture methods need to be continuously improved The Add range of commercial soft multifocal CLs [68] Smooth connection Current problems for multifocal CL designs: • Reduce the dependence of CLs on pupil sizes • Increase Add powers (>3.5 D) • Smooth lens surfaces • Minimal machining errors Curvature continuity ? Continuity problem of zonal aspheric designs Research Objectives  Development of a design method of symmetric simultaneous multifocal CLs with: • Various given smooth power distributions with high Add values • Uniform optical power in large central zone • Smooth anterior optical surface profiles with cubic NURBS curves  A comprehensive method from clinical requirements for calculation and output data for analysis and manufacture Research summary Chapter Chapter Design & manufacture method of multifocal CLs Chapter Chapter Chapter 6: Conclusion and recommendation Chapter Overview of contact lens design Contact lens history 10 Conclusions and Recommendations Conclusions This study has developed a new and efficient design method of simultaneous multifocal CLs to adapt various given smooth power distributions with high Add power values and uniform power in large central zones for different pupil diameters by optimizing three parameters of NURBS curves The mathematical functions have been developed to generate various smooth power profiles based on clinical requirements A solution for design of soft multifocal CLs with uniform optical power in large center– distance zones has been proven Z-shrinkage errors in IM process of the anterior SMs corresponding to the anterior surfaces of multifocal CLs are minimized by both optimizing IM parameters and compensating Addcenter powers This developed method has been verified and proven the feasibility by experiment results of both rigid and soft multifocal CLs 53 6/5/2018 Recommendations The current design program can be also developed to simulate the optical performance directly in Matlab This method can be extended to design and manufacture soft multifocal CLs having three optical zones This method can be extended to design nonsymmetric CLs to correct astigmatism of human eye with NURBS surface In addition, this method can be applied to design other optical lenses with freeform surfaces 54 6/5/2018 Unsuccessful design Contributions This study has introduced a new method to design and manufacture multifocal CLs and its calculation program has been developed i.e Graphical User Interfaces (GUI) in MATLAB The soft multifocal CLs made by this method have been distributed on the market as commercial products Commercial soft multifocal CLs Design program of multifocal CLs in Matlab 55 Paper list L T Vu, C C A Chen, C.C Lee, and C W Yu, "Compensating additional optical power in the central zone of multifocal contact lens for minimization of shrinkage error of shell mold in injection molding process," Applied Optics 57(12): 2981-2991 (2018) SCI, IF: 1.65 (Q2: 50/92, Optics) L T Vu, C C A Chen, and C W Yu, "Optical design of soft multifocal contact lens with uniform optical power in center-distance zone with optimized NURBS," Optics Express 26(3): 3544-3556 (2018) SCI, IF: 3.307 (Q1: 17/92, Optics) L T Vu, C C A Chen, and J T P Shum,"Analysis on multifocal contact lens design based on optical power distribution with NURBS," Applied Optics 56(28): 7990-7997 (2017) SCI, IF: 1.65 (Q2: 50/92, Optics) C C A Chen, L T Vu, and Y T Qui, "Study on Injection Molding of Shell Mold for Aspheric Contact Lens Fabrication," Procedia Engineering 184: 344-349 (2017) SCOPUS L T Vu, C C A Chen, and Y T Qui, “Optimization of aspheric multifocal contact lens by spline curve,” SPIE/COS Photonics Asia, SPIE (2016) EI Conferences Present at Advances in Materials and Processing Technologies Conference (AMPT 2016), 8-11 November 2016 Kuala Lumpur, Malaysia Present at SPIE/COS Photonic Asia Conference, 12-14 October 2016, Beijing, China Patent L T Vu, C C A Chen, and Y T Qui, “Progressive multifocal contact lens and producing method thereof” US 2018/0024380 A1 and TW I584022 (2017) Projects Implement “Research on Modular Design in Soft Multifocal Contact Lens” sponsored by Seinoh Optical Co., Ltd (Sept 2017-Feb 2018) to develop a design program of commercial multifocal contact lenses Implement “Research on Core Reverse Design in Soft Multifocal Contact Lens” sponsored by Seinoh Optical Co., Ltd (March-Sept 2017) to design and manufacture commercial multifocal contact lenses Acknowledgement There are a number of people to whom I would like to express my sincere appreciation for their assistance: I am particularly grateful to Prof Chao-Chang A Chen, my advisor, who not only shared the perspectives, knowledge, expertise, and passion, but also provided a genuine caring presence throughout the journey I would like to express my appreciation to Taiwan Tech for the scholarship during four years and Department of Mechanical Engineering for the great academic environment I am thankful all members of Precision Manufacturing Lab, especially molding group members for your encouragement and invaluable contributions I am deeply thankful to Dr Patrick Joi-Tsang Shum and his company, Fantasee Incorporated and to Mr Shiang Yao, Jeng and his company, Seinoh Optical Co., Ltd for very important 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