Patent ID: 8520323

Claim:
A method for forming a Fresnel lens with corrected micro-defects, comprising: obtaining a Fresnel lens body, the Fresnel lens body including a unitary body of lens material shaped into a plurality of raised lens segments on a planar base, each pair of adjacent raised lens segments on the planar base forming a respective groove in a first side of the Fresnel lens body above the planar base, and respective bottom corners of one or more of the grooves including surface or shape irregularities deviating from respective designed surfaces of the grooves; applying a measured amount of a liquid coating material on the first side of the Fresnel lens body, where the measured amount of liquid coating material forms a meniscus within each of the respective bottom corners of the grooves; and solidifying the liquid coating material applied on the first side of the Fresnel lens body such that at least some of the liquid coating material below the meniscuses solidifies within and fills the surface or shape irregularities in the respective bottom corners of the one or more of the respective grooves.