Quantitative evaluation of performance of 3D printed lenses

Design and fabrication of a lightweight 3D first surface mirror aluminized by DC magnetron sputtering

Aluminum thin films were deposited on a 3D prototype employing the direct current magnetron sputtering technique to fabricate a lightweight 3D first surface mirror. Before the aluminizing, the surface of the prototypes was evaluated with interferometry and atomic force microscope (AFM). The thin films were characterized using profilometry, UV-Vis spectroscopy, x-ray diffraction, AFM, x-ray photoelectron spectroscopy (XPS), and scanning electron microscopy. High adherence and homogeneous deposition of the aluminum's thin films were achieved. In addition, the purity of the material was confirmed by XPS analysis.

3D Printing a Low-Cost Miniature Accommodating Optical Microscope

This decade has witnessed the tremendous progress in miniaturizing optical imaging systems. Despite the advancements in 3D printing optical lenses at increasingly smaller dimensions, challenges remain in precisely manufacturing the dimensionally compatible optomechanical components and assembling them into a functional imaging system. To tackle this issue, the use of 3D printing to enable digitalized optomechanical component manufacturing, part-count-reduction design, and the inclusion of passive alignment features is reported here, all for the ease of system assembly. The key optomechanical components of a penny-sized accommodating optical microscope are 3D printed in 50 min at a significantly reduced unit cost near $4. By actuating a built-in voice-coil motor, its accommodating capability is validated to focus on specimens located at different distances, and a focus-stacking function is further utilized to greatly extend depth of field. The microscope can be readily customized and rapidly manufactured to respond to task-specific needs in form factor and optical characteristics.

Fabrication of biconvex spherical and aspherical lenses using 3D printing

In this work, we present the methods of fabrication and characterization of biconvex spherical and aspherical lenses with 25 and 50 mm diameters that have been created via additive technology using a Formlabs Form 3 stereolithography 3D printer. After the prototypes are postprocessed, fabrication errors ≤2.47% for the radius of curvature, the optical power, and the focal length are obtained. We show eye fundus images captured with an indirect ophthalmoscope using the printed biconvex aspherical prototypes, proving the functionality of both the fabricated lenses and the proposed method, which is fast and low-cost.

Micro-Scale Spherical and Cylindrical Surface Modeling via Metaheuristic Algorithms and Micro Laser Line Projection

With the increasing micro-scale manufacturing industry, the micro-scale spherical and cylindrical surface modeling has become an important factor in the manufacturing process. Thus, the micro-scale manufacturing processes require efficient micro-scale spherical and cylindrical models to achieve accurate assembly. Therefore, it is necessary to implement models to represent micro-scale spherical and cylindrical surfaces. This study addresses metaheuristic algorithms based on micro laser line projection to perform micro-scale spherical and cylindrical surface modeling. In this technique, the micro-scale surface is recovered by an optical microscope system, which computes the surface coordinates via micro laser line projection. From the surface coordinates, a genetic algorithm determines the parameters of the mathematical models to represent the spherical and cylindrical surfaces. The genetic algorithm performs exploration and exploitation in the search space to optimize the models’ mathematical parameters. The search space is constructed via surface data to provide the optimal parameters, which determine the spherical and cylindrical surface models. The proposed technique improves the fitting accuracy of the micro-scale spherical and cylindrical surface modeling performed via optical microscope systems. This contribution is elucidated by a discussion about the model fitting between the genetic algorithms based on micro laser line projection and the optical microscope systems.

Maximizing transmittance in two-photon 3D printed materials for micro-optics in the visible

We characterize three commercial resins suitable for three-dimensional two-photon printing of mm³ volume micro-optical components for visible light - IP-S, IP-n162, and IP-Visio - under different print modes and post-processing conditions. Due to the combination of cured resin absorption and bulk scattering, we find a maximum total printed thickness of 4 mm (or greater) for at least 50% transmittance of red light, up to 2 mm for green light, and large maximum thickness variation for blue light (0.1 to 1 mm).

Application of Bioprinting in Ophthalmology

Three-dimensional (3D) bioprinting is an emerging technology that is widely used in regenerative medicine. With the continuous development of the technology, it has attracted great attention and demonstrated promising prospects in ophthalmologic applications. In this paper, we review the three main types of 3D bioprinting technologies: Vat polymerization-based bioprinting, extrusion-based bioprinting, and jetting-based bioprinting. We also present in this review the analysis of the usage of both natural and synthesized hydrogels as well as the types of cells adopted for bioinks. Cornea and retina are the two main types of ocular tissues developed in bioprinting, while other device and implants were also developed for the ocular disease treatment. We also summarize the advantages and limitations as well as the future prospects of the current bioprinting technologies based on systematic reviews.

3D Printing in Eye Care

Three-dimensional printing enables precise modeling of anatomical structures and has been employed in a broad range of applications across medicine. Its earliest use in eye care included orbital models for training and surgical planning, which have subsequently enabled the design of custom-fit prostheses in oculoplastic surgery. It has evolved to include the production of surgical instruments, diagnostic tools, spectacles, and devices for delivery of drug and radiation therapy. During the COVID-19 pandemic, increased demand for personal protective equipment and supply chain shortages inspired many institutions to 3D-print their own eye protection. Cataract surgery, the most common procedure performed worldwide, may someday make use of custom-printed intraocular lenses. Perhaps its most alluring potential resides in the possibility of printing tissues at a cellular level to address unmet needs in the world of corneal and retinal diseases. Early models toward this end have shown promise for engineering tissues which, while not quite ready for transplantation, can serve as a useful model for in vitro disease and therapeutic research. As more institutions incorporate in-house or outsourced 3D printing for research models and clinical care, ethical and regulatory concerns will become a greater consideration. This report highlights the uses of 3D printing in eye care by subspecialty and clinical modality, with an aim to provide a useful entry point for anyone seeking to engage with the technology in their area of interest.

Optical elements from 3D printed polymers

3D printing belongs to the emerging technologies of our time. Describing diverse specific techniques, 3D printing enables rapid production of individual objects and creating shapes that would not be produced with other techniques. One of the drawbacks of typical 3D printing processes, however, is the layered structure of the created parts. This is especially problematic in the production of optical elements, which in most cases necessitate highly even surfaces. To meet this challenge, advanced 3D printing techniques as well as other sophisticated solutions can be applied. Here, we give an overview of 3D printed optical elements, such as lenses, mirrors, and waveguides, with a focus on freeform optics and other elements for which 3D printing is especially well suited.

Optical transmittance of 3D printing materials

The increasing prevalence of three-dimensional (3D) printing of optical housings and mounts necessitates a better understanding of the optical properties of printing materials. This paper describes a method for using multithickness samples of 3D printing materials to measure transmittance spectra at wavelengths from 400 to 2400 nm [visible to short-wave infrared (IR)]. In this method, 3D samples with material thicknesses of 1, 2, 3, and 4 mm were positioned in front of a uniform light source with a spectrometer probe on the opposing side to measure the light transmittance. Transmission depended primarily on the thickness and color of the sample, and multiple scattering prevented the use of a simple exponential model to relate transmittance, extinction, and thickness. A Solidworks file and a 3D printer file are included with the paper to enable measurements of additional materials with the same method.

3D Printed Contact Lenses

Although the manufacturing processes of contact lenses are well established, the use of additive manufacturing for their fabrication opens many new possibilities to explore. The current study demonstrates the fabrication of personalized smart contract lenses utilizing additive manufacturing. The study includes 3-dimensional (3D) modeling of contact lenses with the assistance of a computer aided designing tool based on standard commercial contact lens dimension, followed by the selection of the suitable materials and 3D printing of contact lenses. The 3D printing parameters were optimized to achieve the desired lens geometries, and a post processing treatment was performed to achieve a smooth surface finish. The study also presents functionalized contact lenses with built-in sensing abilities by utilizing microchannels at the contact lens edges. Tinted contact lenses were printed and nanopatterns were textured onto the contact lens surfaces through holographic laser ablation. 3D printed contact lenses have advantages over conventional contact lenses, offering customized ophthalmic devices and the capability to integrate with optical sensors for diagnostics.

Multi-element lenslet array for efficient solar collection at extreme angles of incidence

Photovoltaics (PV) are a versatile and compact route to harness solar power. One critical challenge with current PV is preserving the optimal panel orientation angle with respect to the sun for efficient energy conversion. We experimentally demonstrate a bespoke multi-element lenslet array that allows for an increased power collection over a wide field of view by increasing the effective optical interaction length by up to 13 times specifically at large angles of incidence. This design can potentially be retrofitted onto already deployed amorphous silicon solar panels to yield an increased daily power generation by a factor of 1.36 for solar equivalent illumination. We 3D printed an optical proof of concept multi-element lenslet array to confirm an increase in power density for optical rays incident between 40 and 80 degrees. Our design indicates a novel optical approach that could potentially enable increased efficient solar collection in extreme operating conditions such as on the body of planes or the side of buildings.

Fabrication of optical components using a consumer-grade lithographic printer

The ability to 3D print optical elements will greatly expand the accessibility of optical fabrication. Here, we report on two fabrication techniques for plano-convex lens files using a consumer-grade lithographic printer. Lenses were post-processed using a simple spin coating technique with the resin used in the printing process or by curing directly on glass concave lenses. Average RMS roughness values were between 13 and 28 nm and RMS wavefront deviations were between 0.297 and 0.374 wave for spin-coated lenses. The average roughness RMS for the glass-cured lenses was 6 nm and the average form RMS was 0.048 wave.

3D Models in the Diagnosis of Subglottic Airway Stenosis

PURPOSE

Preoperative assessment of benign subglottic stenosis is usually performed by endoscopy and a computed tomography scan. Both diagnostic modalities have relevant limitations and sometimes an accurate assessment of the extent of disease is challenging.

DESCRIPTION

Based on computed tomography scans of benign glotto-subglottic stenosis and a control airway, color-coded three-dimensional (3D) models were produced using a commercially available 3D printer. The diagnostic relevance of 3D models was tested by means of a quiz.

EVALUATION

52 thoracic surgeons from 4 North American and 1 European institution with different levels of experience in airway surgery were invited to test the diagnostic accuracy of 3D models against endoscopy films and computed tomography scans. 3D models were found to be superior to the other two diagnostic tools in terms of grading the extent of the stenosis and selecting the correct surgical strategy. The group of residents benefited the most from the 3D models.

CONCLUSIONS

3D models of complex glotto-subglottic airway stenosis are a useful supplement of the preoperative assessment. In addition, they can serve as a teaching tool for residents and fellows.

Advances in Optical Sensing and Bioanalysis Enabled by 3D Printing

The recent explosion of 3D printing applications in scientific literature has expanded the speed and effectiveness of analytical technological development. 3D printing allows for manufacture that is simply designed in software and printed in-house with nearly no constraints on geometry, and analytical methodologies can thus be prototyped and optimized with little difficulty. The versatility of methods and materials available allows the analytical chemist or biologist to fine-tune both the structural and functional portions of their apparatus. This flexibility has more recently been extended to optical-based bioanalysis, with higher resolution techniques and new printing materials opening the door for a wider variety of optical components, plasmonic surfaces, optical interfaces, and biomimetic systems that can be made in the laboratory. There have been discussions and reviews of various aspects of 3D printing technologies in analytical chemistry; this Review highlights recent literature and trends in their applications to optical sensing and bioanalysis.

Three-Dimensional Printing of Nonlinear Optical Lenses

In the current paper, a series of nonlinear optical (NLO) active devices was prepared by utilizing stereolithographic three-dimensional printing technique. Microcrystalline NLO active component, urea, or potassium dihydrogen phosphate was dispersed in a simple photopolymerizable polyacrylate-based resin and used as the printing material to fabricate highly efficient transparent NLO lenses. The nonlinear activity of the printed lenses was confirmed by second-harmonic generation measurements using a femtosecond laser-pumped optical parametric amplifier operating at a wavelength of 1195 nm. The three-dimensional printing provides a simple method to utilize a range of NLO active compounds without tedious crystal growing and processing steps. Furthermore, introducing NLO additives in the printing material provides an easy and cost-efficient way to manufacture lenses with NLO functionality.

3D printed fiber optic faceplates by custom controlled fused deposition modeling

A 3D printing technique for manufacturing air-clad coherent fiber optic faceplates is presented. The custom G-code programming is implemented on a fused deposition modeling (FDM) desktop printer to additively draw optical fibers using high-transparency thermoplastic filaments. The 3D printed faceplate consists of 20000 fibers and achieves spatial resolution 1.78 LP/mm. Transmission loss and crosstalk are characterized and compared among the faceplates printed from four kinds of transparent filaments as well as different faceplate thicknesses. The printing temperature is verified by testing the transmission of the faceplates printed under different temperatures. Compared with the conventional stack-and-draw fabrication, the FDM 3D printing technique simplifies the fabrication procedure. The ability to draw fibers with arbitrary organization, structure and overall shape provides additional degree of freedom to opto-mechanical design. Our results indicate a promising capability of 3D printing as the manufacturing technology for fiber optical devices.