Diffractive waveguides require either an airgap or low-refractive coating to function optimally. At Addoptics, we've pioneered an innovative technique for direct casting encapsulation around these waveguides while preserving the crucial airgap. Our advanced solution integrates ophthalmic-quality lenses with precise mechanical geometries in a single component, delivering superior optical performance without compromising structural integrity.
The challenge
Creating a custom prescription solution for airgapped diffractive waveguides presents significant technical challenges. The requirement to maintain precise optical properties while ensuring structural integrity demands innovative engineering approaches. The unique requirements of these advanced optical systems include:
- Maintaining critical airgap tolerances while incorporating prescription correction requires precision engineering at microscopic scales
- Standard encapsulation methods risk contamination or deformation of the delicate diffractive structures
- Thermal expansion differences between materials can compromise optical performance in varying environmental conditions
The Study
Our study on diffractive waveguide embedding developed methods for preserving airgaps while encapsulating waveguides in prescription lens materials. We tested precision casting techniques while evaluating optical performance and shape accuracy. Throughout the process, we maintained focus on mass manufacturability and ease of handling.
The Solution
This study has yielded two complementary solutions to meet diverse client needs:
- Direct Waveguide Casting: By directly casting onto the waveguide, we achieve unprecedented optical alignment precision while eliminating assembly tolerances. This premium solution delivers maximum light transmission and structural integrity—perfect for demanding applications where optical performance cannot be compromised.
- Modular Cover Assembly: Our alternative approach separates the casting and waveguide components, enabling rigorous quality assurance at each manufacturing stage. This design facilitates simplified maintenance and offers greater production flexibility, potentially reducing costs for specific implementation scenarios.