US 12,459,220 B2
Additive manufacture of application-specific inorganic optical elements
George Melville Williams, Jr., Vashon, WA (US); John Paul Harmon, Albany, OR (US); and Thomas Leonard Allen, Milwaukie, OR (US)
Assigned to Vadient Optics, LLC, Tualatin, OR (US)
Appl. No. 18/880,980
Filed by Vadient Optics, LLC, Tualatin, OR (US)
PCT Filed May 28, 2024, PCT No. PCT/US2024/031229
§ 371(c)(1), (2) Date Jan. 3, 2025,
PCT Pub. No. WO2024/249398, PCT Pub. Date Dec. 5, 2024.
Claims priority of provisional application 63/504,543, filed on May 26, 2023.
Prior Publication US 2025/0170790 A1, May 29, 2025
Int. Cl. B29D 11/00 (2006.01); B29C 64/112 (2017.01); B33Y 40/20 (2020.01); B33Y 80/00 (2015.01); G02B 3/00 (2006.01); B29K 105/00 (2006.01); B29K 105/16 (2006.01); B33Y 10/00 (2015.01)
CPC B29D 11/00355 (2013.01) [B29D 11/00 (2013.01); B33Y 40/20 (2020.01); B33Y 80/00 (2014.12); G02B 3/0087 (2013.01); B29C 64/112 (2017.08); B29K 2105/0061 (2013.01); B29K 2105/162 (2013.01); B33Y 10/00 (2014.12)] 25 Claims
OG exemplary drawing
 
1. A method for making an optical element, the method comprising:
receiving in a printing device a plurality of liquids, each liquid including a volatile solvent and a non-polymerizable matrix, wherein one or more of the liquids also includes a suspension of particles;
receiving in the printing device a plurality of print maps corresponding to the plurality of liquids, each print map defining a pattern of application of the corresponding liquid for a series of pre-sintered layers of the optical element;
for each pre-sintered layer, operating the printing device to:
deposit the plurality of liquids as a plurality of spatially patterned droplets according to the patterns defined in the plurality of print maps for that pre-sintered layer, and
use a drying source to dry the pre-sintered layer to remove the volatile solvent from the spatially patterned droplets; and
sintering the series of pre-sintered layers to form a vitreous monolith comprising the optical element.