Electrochromic, flex cable or even a touch pad. Embedding flexible films comes with its own unique set of challenges. Something that thus far has only been solved using a substrate followed by a laminar stack. We can do better.
The challenge
Integrating flexible films into eyewear presents a significant technical challenge. While these films can naturally conform to the curvature of lenses, which makes them ideal for thin ophthalmic applications, securing them properly within the lens structure requires innovative solutions. The primary obstacles we face include:
- Maintaining precise positioning during the casting process to ensure optimal functionality
- Preventing delamination or movement of the film after repeated use and temperature variations
- Achieving seamless integration without compromising optical clarity or increasing overall thickness
- Partial encapsulation. Encapsulate the film while keeping the electronics free of contamination.
The study
We've developed solutions for precise alignment, shrinkage compensation, and material reduction challenges in embedded thin films. Our proprietary gentle casting process, combined with our expertise in creating complex prototypes, positioned us perfectly to address this technological challenge. We've validated our approach by successfully casting thin films while keeping part of the connecting cable free from encapsulation, enabling easy assembly and electrical connection. This innovative encapsulation technique ensures the sensitive thin film components are protected within the lens structure while maintaining accessible connection points for system integration.
The Solution
Leveraging our innovative patented technology, we've developed a groundbreaking method to direct cast prescription lenses with embedded flexible films. Our precision-engineered component holders guarantee exact placement within the lens structure, while carefully controlled low injection speeds and temperatures create an optimal environment that preserves the integrity of the electronic components.
The flexible thin films match up perfectly with our ability to cast ultra thin lenses, resulting in one of the thinnest and lightest solutions for prescription smart eyewear to date. By direct casting custom prescriptions with integrated electronics, our solution achieves a profile significantly thinner than any conventional approach. This revolutionary manufacturing technique allows us to overcome the space limitations that have previously hindered the development of truly wearable smart eyewear.
The Result
This revolutionary process results in ultra thin and lightweight prescription lenses with fully embedded thin films. Our direct cast technology makes the lenses ready to use straight out of our facility. Connect the electronics, assemble the glasses and you’re good to go.