Patent ID: 8795558

Claim:
A method of forming an ophthalmic lens, the method comprising: providing a volume of reactive mixture material into a container the shape of which does not influence the shape of the ophthalmic lens; placing a male mold having an optical quality surface at least partially within said volume of reactive mixture such that at least a part of a convex surface of said male mold is submerged within said reactive mixture; creating a digital 3-D mathematical model defining corrective needs of an eye; generateing a script comprising multiple projection paths and time durations of actinic radiation; and projecting a first pattern of actinic radiation comprising UV light through the male mold along at least a part of the submerged convex surface of said male mold, wherein the first programmed pattern is based upon the control of a digital mirror device via said generated script, wherein said first programmed patterns of UV light cures a selected portion of said volume of reactive mixture in a free-form manner on a voxel by voxel basis to form gelled reactive mixture such that a distal side of the gelled reactive mixture from the male mold surface does not contact a mold surface, and wherein the gelled reactive mixture forms a first side of said ophthalmic lens that is an optical quality arcuate shape which is generally defined by said male mold surface and which extends on a voxel by voxel basis to a surface based upon a depth of cure of each respective voxel reaching a gel point on the distal second side; subsequently processing a fluent media in fluid contact with the second side to form a second, optical quality opposing side of said ophthalmic lens.